The document discusses prefabrication in construction, including current challenges and future opportunities. It covers: 1. The context of needing more cost-efficient, high-performing buildings. 2. Current prefab systems using various materials and construction methods, and their general benefits like quality, speed, environmental impact. 3. Moving towards more integrated prefab systems to aid the energy transition and meet renovation needs, through innovations like BIM, geothermal energy piles, and concrete activation. 4. The push to renovate existing building stock, and how prefab techniques may help with renovation projects. 5. Potential future directions, like innovative materials, fully integrated modular structures,

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
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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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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
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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
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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
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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
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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
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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 . . .

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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

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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