The best Know-how and IT solutions in the Precast Concrete market

Transcription

1 The best Know-how and IT solutions in the Precast Concrete market Software Technology Consultancy CSG is the European leader for Technical Services in the Precast Concrete market. Since 80s, CSG provides the major Companies the most integrated and advanced IT solutions and methods, assuring the best integration, time and cost saving between Design, Calculation, Project Management and Work Management. Solutions are applied for Industrial, Commercial, Housing Buildings, and Infrastructures.

2 The Winning Partner IT Solutions Specific for Precast - Fully Integrated - Architectural Drawing - Structural Analisys - Executive Design - Production Planning - Accounting - IT and Engineering Support - Without Competitors Consultancy For Governments, Investors, Building Companies, Manufacturers - Technology Solutions - Re-Engineering - Business Plans - Training Courses - Precast Plant setup Projects Housing, Industrial, Logistic, Infrastructure, Parking, Shopping Center, Bridge, etc. Achievements - Milan Intl. Airport - Saint Gobain factory - IKEA Shopping Center - University of Milan MAIN REFERENCES

3 Architectural Design 3D Model Structural Calculation Knots Executive Project Panels Project Automation of production INTEGRATED DESIGN AND CALCULATION FOR PRECAST STRUCTURES LegoCad allows a design of precast elements for construction of industrial buildings, simulate all production processes and assembly stages. Once the building is assembled, the system is able to generate all the production reports with assembly diagrams. It is clear that, in order to be more competitive today, in addition to technologically advanced equipment, an efficient corporate organization is fundamental. This allows the best use of resources and highlights departments productivity in real time, in order to understand market changes, which products and orders are mostly required and convenient and which departments can be subject to cut. The proposed solution is made of two fully integrated software packages: LegoCad for technical drawings and P2000 for data management. LegoCad consists of the following modules: ARCHITECTURAL DESIGN Easily generate an architectural design for the proposal Optional 3D animation and rendering Improvement (quality and speed) in design execution Integration of proposal with the drawing Reduction of mistakes due to lack of attention or wrong quotation Uniformity of drawings STRUCTURAL CALCULATION Loads definition Frame meshing and automatic loads analysis Calculation according to Euro Codes or local seismic requirements Calculation report generation, columns checks. EXECUTIVE DESIGN Connection inserts and anchors positioning Initialization and automatic development of production reports from the architectural drawings Uniformity of drawings and notes for production and storage Drawings for the production integrated with the bill of materials (orders and store control) The basic information, managed by the program, enable less people dependency and a better business organization

4 Estimate and Statistics CRM - Customer relationship management Project management Production Planning Tags Production IT ORGANIZES AND MANAGES QUALITY IN YOUR COMPANY P2000 is a valuable support to good corporate organization. It aims to monitor the activities of departments in enterprises and to control production costs with sales prices. ESTIMATES Offers with cost analysis more realistic. Lower expertise needed to assess difficulties of works. Possibility to understand and evaluate instantly all estimates of the commercial network. Automatic updating costs on the basis of market value. Adaptation of traditional prices.. PROJECT MANAGEMENT AND PRODUCTION The design is automatically transferred to this module, reducing errors made during inserting data, especially in case of variations. Better control in the different working stages. Availability of each element through bar code. Consultation view of the situation of each element. CSG Information Technology via Panini FIORENZUOLA D'ARDA (Pc) TEL: FAX: info@csgit.it - PLANNING PRODUCTION Management of moulds occupancy schedule. Ability to assess the timing of production and to make any change to optimize production and meet delivery times. Assessment of delivery times. MANAGEMENT CONTROL AND BUDGET VERIFICATION Verification of costs from start to order execution. Comparison of the estimate between committed order and production. Check Quantity of materials or their economic values. WELCOME TO THE PRECAST CONCRETE WORLD

5 ARCHITECTURAL DESIGN The name LegoCad represents the way a building is assembled; this software is based on a data-base of parametric formwork and is customized for each client. It allows a three-dimensional architectural assembly of the building, while operating with a two-dimensional approach. After defining a structural mesh, columns, consoles, coverage elements, slabs and walls are positioned; in the design assembly phase changes and modifications can be made at any time. All drawings (views) are complete with dimensions that are automatically positioned, these drawings contain all elements needed for design; the position of the details are optimized following standardization requirements from different Customers. Eventually when the design is changed all the drawings are updated automatically (drawings and quotas).

6 All the elements used in the architectural composition are listed, with their geometrical details, in separate reports used in the computation of proposals, orders, production and purchase departments.

7 3D MODEL LegoCad allows to create a 3D model compatible with Autocad and 3D Studio and to define the construction materials; a procedure is available to quickly define the environment (sky, landscape, trees, etc...) that surrounds the building. Cast stone Other materials Frames Concrete While presenting the proposal, it is useful to attach a drawing with a realistic picture of the building enabling the customer to understand what he is going to build; for the precast manufacturer this is also a way to differentiate itself from competitors.

8 With LegoCad it is possible to manage different types of panels finishing (homogeneous, horizontal squares, vertical squares) and for each area assign a material that is reported in the 3D model. Parametric and color customized joints Customizable cast stone Windows where transparent or reflective materials and customizable color frames are applicable This simple procedure allows to fast obtain a 3D model complete with camera view.

9 STRUCTURAL CALCULATION LegoCad is able, starting from the architectural design, to develop the 3D frame of the structure and to calculate the self - weights of each element related to its geometric and mechanical characteristics. The program also allows to assign dead and live loads, directly applied to the structural elements. The structural frame obtained can be interfaced with various calculation and verification programs. During the calculation phase, linear and non linear static analysis (included second geometric order), dynamic modal response spectrum analysis are performed, according to existing rules (eg. Euro Codes) and as required by the customer. It is possible to get both graphical and numerical information from results of calculation; the deflected shape of structure and actions diagrams for each element can be shown.

10 The results are grouped into a database for easy consultation, allowing a flexible and fast identification of critical strength-displacement situations. Output data list is defined by user. Assuming a type of steel reinforcement and stirrups for the column, it is finally possible to calculate the resistant interaction curve for all significant sections and check them.

11 KNOTS The fixing connections are very important for the concrete precast structures because, through them, the linkages among the different structural elements that constitute the building are executed. The connections are subject to vertical and horizontal actions, as for example their own weight, wind and seismic actions, and for this reason they must be designed and checked to transmit all the stress actions, to prevent sinkings or settlements not expected in the design phase. Once the architectural design phase is ended, LegoCad allows to analyze and to position the knots that fix the structural precast elements to each other. Knots loaded in LegoCad can be commercial connections or user defined connections. Only in specific situations (non standard knots ) the inserts will be positioned one by one. LegoCad includes an archive of standard knots (commonly used in the market and used by concrete manufacturer) for the following connections: Footing Column Column Beam Beam Beam Beam Slab Panel Column Panel Beam Panel Slab Panel Panel Slab - Dome Panel - Panel

12 During knots insertion, once the user has defined the type of connection to be used, LegoCad goes on by placing the respective inserts (boxes, profiles, ) on the different elements considering the production companies rules, also checking distances from elements side, the capacity for suspension elements, any interference among different inserts. When restrictions are not respected LegoCad reports the error to the user. How to use Example of panel-column knot: Once the architectural design is ended, the user chooses, from the KNOT menu, the knot typology to insert, for example panel column (PAN-COL). Automatically all typologies on market and stored in the archive are proposed. After choosing the knot, the user, driven step by step by the program, defines the elements where to apply the inserts. The program automatically positions the inserts, building the knot, on the panel and on the column. Any change in the knot position on the architectural design will determine the update of the inserts positions in the elements carpentry drawings. In specific situations, when it is not possible to use commercial knots, it is possible to use generic knots defined by the user. While closing the order, the program automatically generates the used knots and the kit cast and assembly inserts summaries.

13 EXECUTIVE DESIGN After the architectural design and the Customer s order confirmation, the executive design will start with the positioning of the knots and of the joints between the various precast elements (panels - columns, panels - beams, panels - panels, beams - columns, etc...). The use of appropriate macros, that calculate the elements weights and consider the typical dimensions of the connections, allows to position automatically each joint on the related precast elements and to validate compliance with the knots rules avoiding the use of incorrect joints. After having completed the model of the building, LegoCad is able to identify all the elements, recognize the different ones (by size, form, inserts ) and assign a code to each one, update the assembly tables, draw up the production sketches for carpentry, reinforcements and inserts and provide all calculations of materials used in the project.

14 With this system production sketches are always drawn up in a uniform way; to facilitate its use a document (called STP) is provided to describe the reading and use specifications of architectural and executive design produced by LegoCad.

15 PANELS DESIGN General Parameters: - Geometrical features, characteristics of materials (including maximum strengths allowed for different verification step ), steel reinforcements logic and positioning of polystyrenes, abutment stones. - Loads agents: in addition to own weight, wind (allocation of increased involved area), earthquake. Analysis of stress in various steps: - Shakeout - Lifting - Own weight - Wind - Earthquake Calculation of minimum areas of reinforcement. K heat: Calculation of thermal conductivity, carried out in accordance with the standards UNI EN ISO 6946 and subsequent changes. The amount of heat that passes through the panel is calculated considering the material type and sections. Kn Ko

16 Distribution of reinforcements in panel edge beams: Design verification report:

17 PRODUCTION AUTOMATION The integration between the design and production processes makes possible to reset errors, to reduce the time needed to communicate between technical and production departments, to avoid conflicting documents because of missing updates and manage Customer s change requests in real-time. The designer enables the production of the verified elements and not subject to variations, he may also assign assembly stages related priorities to buildings constraints or to sequence of the assembly itself. The technical designer defines the filling of moulds for the coming working days selecting elements of the same order. For example picking one panel, this is placed on the mould, it is hatched and the date of production planning is added. It is possible to optimize production, switching from one order to another; the production plan can be easily updated using commands like move day of production, re-optimize mould etc.

18 The planning can provide the following reports for each day / cycle processing (sorted by positioning mould): Layout general drawing including the percentage of capacity usage. Drawings of each mould Summary of concrete, cast stones and finishing with possible separation between 1st and 2nd cast. Summary of inserts, connections, lifting and lightening sized elements. Summary of steel reinforcements by type, diameter and moulding. Executive sketches of the precast elements, in this way the table is printed at the time of production and there is no risk to have not updated versions. Production cards with code and characteristics of precast elements. CAD-CAM files UNITECHNIK format needed for production automation, for the geometry of the elements, the positioning of inserts, the types of processing, etc. CAD-CAM files BVBS format for reinforcement cuts and bending. Update the production plan in the medium - long term.

19 Estimates and Statistics CRM - Customer relationship management Order management Production Planning Production Tags IT ORGANIZES AND MANAGES QUALITY IN YOUR COMPANY P2000 is a valuable support to a good corporate organization. It aims to monitor the activities of enterprises departments and to control the production costs with sales prices. The precast market is increasingly competitive, as new technologies are available (quarterdecks, materials, etc.). And therefore also the holding of relatively small size is able to equip and market products of good quality at an attractive cost. And now it is clear that, in order to be more competitive today, you need, in addition to technologically advanced equipment, even a good corporate organization. This allows you to maximize the use of resources and highlight real-time productivity of departments in order to understand how the market moves, what products or what kinds of orders it is better to invest in and what is advisable for departments to possibly cut. P2000 is the software solution that CSG offers. This program combines the convenience and ease of use in a Windows environment with the various features of its instruments. The Integration of P2000 involves all branches of a company to coordinate their work and to play.

20 AUTOMATION AND QUALITY OF A PRECAST COMPANY Companies that benefit from this software see as this system a valuable tool in a more competitive market. People working in these companies do not fear for verification or constructive checks on the daily activities, but they are encouraged to improve their professionalism. Consisting of several modules integrated with each other, P2000 is a comprehensive tool for a company that decides to automate its work in a quality manner. Estimates Offers with more realistic cost analysis. Lower expertise needed to assess difficulties of works. Possibility to understand and evaluate instantly all quotes of the commercial network. Automatic updating of costs on the basis of market value. Adaptation of traditional prices. Planning Production Management of moulds occupancy schedule. Ability to assess the timing of production and to make any change to optimize production and meet delivery times. Assessment of delivery times. Project Management and Production Management Control and Budget Verification The design is automatically transferred to this module, reducing errors made inserting data, especially in case of variations. Better control in the different working stages. Availability of each element through bar code. Consultation view of the situation of each element. Verification of costs from start to order execution. Comparison of the quotation between committed order and production. Check Quantity of materials or their economic values. CSG Information Technology VIA PANINI FIORENZUOLA D'ARDA (PC) - ITALY Tel: Fax: info@csgit.it - WELCOME IN THE WORLD OF PREFABRICATION

21 ESTIMATES AND STATISTICS It generates offers through cost rules considering materials and work cycles to properly evaluate the cost of a building. RULES Elements Transportation Assembly Moving from a traditional PRICE LIST to a cost analysis performed for each offers with RULES that assess the quantities of materials, manpower and optimizations at the stage of production and transportation.

22 Statistics Enable assessment of market demand and whether the types of manufactured goods are competitive for more frequent use. Frequent Use of Products Summaries by geographical area or offer state Summaries by agent

23 CRM CUSTOMER RELATIONSHIP MANAGEMENT Today competitive search, passes towards sales force automation. The way the company defines its commercial strategy is crucial for results in terms of acquired orders. The client has specific expectations on the behaviour of the trade negotiations and in stages immediately preceding and following the sale. New contacts are favourably impressed by sales representatives leaving a clear image of a well-organized and managed company. Older customers stay more easily faithful to a company that, every day, considering its promotions, does not forget the needs of each customer, previous purchases, problems met and solved.

24 Standardizing sales deals is among the first targets; a clear business strategy that involves the identification of the main cornerstones with the identification of various sales paths, facilitates the reporting of situations and related statistics. For commercial there are operational benefits using these software functions, such as the ability to manage various stages, to follow the progress and to record intermediate states and product documents. In managing a sales network, sales force automation is essential, because it presents an image of an organized and homogeneous company and the customer favourably perceive that all commercial actions are consistent with a plan. The sales management will keep under control all negotiations with relevant information and it will then be able to review and adapt its own sales policy also considering the margins of each potential order.

25 ORDERS MANAGEMENT It manages all processes affecting orders, starting from technical department to production, storage, transportation, assembly and any additional works. Project Calculation Design data are automatically transferred to this form, reducing errors while inserting data, especially in case of variations. Production and control in work stages. Better control of the order in its working stages. By collecting all data it becomes easy to define both an economic control by order, and by type of element.

26 Cost Rules Verification The check between the quantity and the amounts provided in the phase of develop of the estimate and the one in the real design, production and budget, allows the refinement of the cost rules used in the proposal.

27 PRODUCTION PLANNING NG The planning system for medium and long term performs an overview of all business operations, defining priorities of execution of orders and capacity of technical department, production, transportation and assembly. A complete plan of all committed orders and offers made is performed This planning includes: all designed orders: these orders can have to be produced only partially, in this case only elements still to be produced are considered. all orders acquired and not yet designed: to the elements of these orders all the information for their dimensional positioning in the mould are already associated. all possible estimates to be acquired: even for these elements, all information needed for production are already present. MOULDS CHART ORDERS CHART

28 Moulds Occupancy Checking of production load by mould with the possibility to make changes to better optimize resources (internal and external) and meet delivery deadlines Delivery planning This module is completed by the SHORT-TERM PLANNING that, based on the planning proposal, defines exactly the elements to be produced in the coming days, considering the schedule of the moulds and trying to keep the delivery commitments.

29 PRODUCTION TAGS Aimed at CE marking, at quality control and at elements tracing rules, tags follow, with a serial number, the life of the elements from the assembly of the reinforcement to the work execution. Print Print all relevant information related to manufactured elements availability and to the movements in Production, Storage and Transportation. Information will be visible to operators or available by reading the bar code printed on the card. Production By reading the bar code the manufactured element will be automatically recorded in the daily production.

30 Warehouse It manages the storage of manufactured elements in the production areas, the barcode enables the identification of all elements by linking the manufactured element with the storage area. Transportation Prints the accompanying document recording the transportation and updating the warehouse status.

31 STRUCTURAL PRE SIZING In the proposal stage an estimate is necessary to define the sections and the typologies of reinforcements of the precast manufactured necessary for the architectural and economic design of the building. CSG proposes through PREDIM an effective answer to obtain correct columns sizing, both by typology and reinforcement quantity. PREDIM, through simple commands, allows the customer to perform: 1. Modeling of the significant plane frame with the positioning of columns, beams, slabs, panels loaded in the program. 2. Allocation of overloads (permanent and variable) of wind and seismic zone DISTRIBUTION OF WIND DISTRIBUTION OF SEISMIC FORFORCES

32 3. Definition of bridge-cranes according to the bearing capacity, the level and movement direction PREDIM, using customer data, performs: 1. Calculation of the axial action and bending moment at the base of each column. 2. Optimal sections and reinforcements of the central and side columns that verifies the base actions on the frame and considering the second order effects.

33 AUTOMATIC CALCULATION OF HORIZONTAL ELEMENTS All the data from the 3D model built with LegoCad can be automatically transferred to Eiseko s programs for automatic Calculation of all reinforcements and automatic creation of the executive drawings.

34 AUTOMATIC WORKING CALCULATION CSG Engineering s.r.l. Via Panini, Fiorenzuola D Arda (PC) Tel Fax info@csgit.it WELCOME IN THE PRECAST WORLD

35 INTERACTION CURVES To properly size precast elements in the offers, it is important to estimate the useful section and the quantity of reinforcement. The use of load diagrams created at the ultimate limit states allows to perform a PRESIZING that will be confirmed by final results of calculations. The use of the COLUMN s interaction curves is particularly useful in case of compression and bending columns with load applied at different levels; such situation is referable to one equivalent column blocked at the base with only one load applied to the extremity and with a new equivalent height H to be used in the interaction curve. The diagram considers also the unfavorable effects of the second order.

36 For the horizontal elements, BEAMS and SLABS, the interaction curves build a relationship among loads and elements length with number of strands and reinforcement incidence. Interaction curves allow to estimate starting from offer phase the real costs of elements. Tabs, executable for each types of prestressed elements, prepared using the input data of the Company (geometry, materials, strands map; rules for stirrups and steel rebars), also considering the fire resistance, provide the optimal combinations for: LENGTH + LOADS STRANDS NUMBER & STEEL INCIDENCE

37 INDUSTRIAL CIVIL SOFTWARE PROGETTAZIONE DI EDIFICI RESIDENZIALI IN CALCESTRUZZO, POLISTIROLO E LATERIZIO CSG Engineering S.r.l. CSG Engineering s.r.l. is an engineering company that operates since thirty years, with national and international Companies, in the precast concrete building design adopting the most advanced and innovative engineering technologies. Our working areas are: architectural and structural design, structural calculation, study of new precast elements typologies, final testing, especially in the residential, industrial and precast area (one-story and multistory buildings, commercial spaces, residential and social housing, logistic and infrustructures). Service offering for precast buildings is complete and able to provide both support and coaching in the following way: - Technical and software consulting services, addressing companies already active in the precast industry, including: New manufacturing typologies study Production issues study and solution Precast buildings projects Consulting for improving automation and quality of enterprise and production - Turn-key services, specifically addressing companies needing a new building system, including: Know-how transfer Support Training Thanks to a great number of employees and suppliers, CSG can solve Customers requirements, even the most complex and urgent.

38 REFERENCE CODES All architectural and executive designs, studies of elements, consulting and final tests are delivered following Euro Codes and national specific DANs in place for what concerns buildings (including fire resistance, seismic analysis, heat conductivity, energy saving and renewable energy, acoustic insulation) and local material characteristics. For execution designs all needed documents will be delivered: graphical tables, technical drafts, construction details (steel, reinforcements, knots, ), calculation and verification reports, eventually needed for getting certification according to active rules in place. INDUSTRIAL Offering an efficient service of architectural and execution design and Customer coaching in all stages: - offer architectural and execution design, - production tables and assembly drawings, - reports creation allowing management control. Delivering consulting and maintenance for technological definition of moulds, steel reinforcements typology optimization and solution of production issues. - CIVIL Study and proposal of technologies to be adopted for residential buildings mono and multistory, all executable with precast elements. The use of industrial technologies in building allows to: - reduced building costs, - reduced assembly time, - reduced skilled manpower, - reduced manpower training time, - reduced works in traditional techniques, - high material quality and certification, - high in finishing, technical plants and insulation (thermal and acoustic). SOFTWARE LegoCad and P2000 software products are essential for managing processes and allow: information management of precast buildings design and production; development of full structure design (from design to executive drawings, included calculation and verification); resource optimization; production planning, manufactures transportation and assembly. CSG Engineering s.r.l. Via Panini, Fiorenzuola D Arda (PC) - ITALY Tel Fax