02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 34
NEWS Features of a BIM system
Assembling precast structures and managing a precast concrete company In this article - after an outlook on the BIM features of the software options relevant for reinforced concrete companies - an analysis of some technical aspects with the objective of obtaining a well functioning system composed of a software and the specific experience of the provider concerning fields of application will be carried out. Also, the aspects regarding organization, changes performed, and the user training needed, in other words, all issues of importance for the success of putting an integrated system into operation, will be dealt with. All activities of a precast company concerning a given project will commence with an assessment of the same by studying architectural drawings and project calculations on the basis of the envisaged precast structures. Thereafter, the development of a corresponding quotation based on the calculation of manpower required on account of the project planning is necessary. If this assessment and the subsequent quotation end up in a contract, all previous information gathered will form a valid basis for supporting production planning and the orders forwarded to relevant suppliers. To control production by analyzing the various activities involved, a comparison of the required resources (labour and material) with the estimated project budget to sensibly incorporate a project into the final annual company balance sheet is necessary. One of the main features that a system must thus provide for every project is a constant exchange of information concerning the activities of the different departments (sales office, technical office, production, services, purchasing, and accounting). Maurizio Frasani, CSG Information Technology S.a.s, Italy Francisco Pedro Oggi, Emporio do Premoldado, São Paulo, Brazil
facilities and its own rules of design and production. All these aspects often lead to errors in the incorporation of these features.
b) An appropriate company organization. c) An integrated software system to be able to manage and monitor most of the activities of the various corporate offices.
Features of an integrated system The illustration given in Fig. 1 shows the information flow required in the different phases of acquisition and order management to ensure that the project in question is at all times logically embedded into ongoing overall company activities. The term “Building Information Modeling (BIM)” refers to the process of creating and handling the information model of a certain building. Any such information will comprise the entire cycle of the project including erection, use and maintenance. BIM also includes a new architectural CAD generation which not only implies the generation and application of simple graphic elements such as lines, polylines, circles, arches etc., but also allows for the planning of technical building components like pillars, beams, attics, walls, load-bearing structures, windows, doors, etc.). The drawings thus generated will also contain the data of necessary components such as geometry, production, location etc. A model thus generated can be employed for calculation, testing and analysis, economic evaluation, production planning and the like, and it can provide links to CAM systems for automated production. There are several generic software programmes that have hitherto been offered to the precast industry, but one of the most salient problems with these programmes is the development of specific libraries for a specific customer as each company has its own precast production 34
CPI – Concrete Plant International – 1 | 2013
Pre-dimensioning structural components Before describing the necessary features of specific software for the precast concrete industry, it appears necessary to give some consideration as to what factors may be nowadays essential in order to obtain a greater degree of competitiveness in the market. These are, in my opinion: a) A technologically advanced equipment permitting the incorporation of CAD/CAM technologies
Studying a project starts with the determination of specific dimensional requirements that often originate from the customer’s drawings and that, in addition to the external dimensions of the building, also show distances (e. g. between pillars) and other overall structural dimensioning aspects. Based on this information, the type, section, and location of the elements to be used in
Order Management Design & Engineering
Sales Dept.
•! ! •! ! ! •! !
Transport & Assembly
Production
•! !
•! !
•! ! •! ! !
•! !
•! ! !
•! !
•! !
•! !
•!!
Fig. 1: Information flow - acquisition and order management www.cpi-worldwide.com
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 35
NEWS Maurizio Frasani studied industrial engineering with a focus on information technology at Politecnico di Milano – School of Management. From 1978 to 1984, he first worked as a technician with a precaster where he was introduced to the technology of precast construction. After working as a freelance consultant for precasting companies from 1985 to 1989, he founded CSG Information Technology in 1990 and became a consultant for major Italian precasting enterprises. This led him to extend his activities as of 1995 to other West European markets such as Spain. In 2000, Frasani became one of the founders of CSG Engineering. In 2004, he enlarged his activities to serve the East European market where he became responsible for the planning and introduction of newly constructed turnkey buildings. Since 2010, Frasani’s company has succeeded in establishing itself on South American markets as well. Francisco Oggi graduated in Civil Engineering at Universidade Presbiteriana Mackenzie, São Paulo, Brazil in 1978. From 1978 – 1992 he worked as a structural designer. In 1987 he founded the company Emporio do Premoldado. From 1992 until today he is precast and tilt-up consultant.
INTERNATIONAL INTERNA ATIONA T L LT LTD D
For a High Quality Mix... Choose a Rapid Mixer
" 1 2 !#1+.)1.0#!"2 ()/+&$
"-!(/2!$!" /+/2 /.#01.0#!"2 #!,)
)"),)$./2 )#++1!.+-$
)%)10.+)2()/+&$
5#-(01.+-$2 5"!$$+$&
4(2 2(22 ! 2( 2
# 2 2
/ 2 2
1 2 2 # 2 2 2 2
/ 2 22 2 22 1!(1!,2
'0(&).20!$.+. 2
!1.0!"20!$.+. 2
M3 Covered...
543332 10/.-,+*)(21-/.2 '0(&).2
1-,,+..)(2 )%)10.)(2(+/)&$
5#-(01.+-$2 5"!$$+$&
5#-(01.+-$ .#!$/5-#.!.+-$ !//),'"
10/.-,+*)(21-/.2 #0")/
-)#2
5 2 2 2 2 2
" 2 2 2 2 2 2 2
5 2 2 2 2 2 2
1 2 22 '0(&).22)%)10.+-$2 5#-(01.+-$22'!"!$1)2
Fig. 2: Macro-functions of an integrated system for the precast concrete industry.
the project can be identified to make proposals to the client that match his own specifications and that at the same time make the best use of a company’s skills and know-how in supporting the intended precast structure. This way, project proposals will be properly sized and economically competitive. For these endeavours, application programmes or performance diagrams can easily be learnt and used even for personnel not skilled in engineering; and such predimensioning will obviously not be the final version. However, if the tool has an appropriate make-up, deviations will be minimal. By using these programme features, it will then be possible to develop a comprehensive library and a simple user interface. Once the type of geometry and the directioning of meshes have been chosen, the design itself can be started.
Architectural design The use of BIM software allows for a database of parametric moulds specific for each www.cpi-worldwide.com
precaster to perform a three-dimensional architectural composition of the building in question. This is accomplished by simulating the stages of production and assembly of the various components used in the construction of the building. There are no generic commands such as "Stretch" but instead commands such as "Pillar Height", "Beam Length" and the like, so that users are allowed to employ their own terminology in a natural work environment and the programme can hence be used instantly. Once the 3D model has been completed, it is then possible to generate all the desired layouts: plans, sections, axonometric and 3D perspectives. Some useful functions in this phase are: - Speedy automatic modelling (mesh, pillars, roofing, plugging, etc.). - Dimensioning systems for automated tables and architectural production; - Rapid changes for variations in decks, structural changes, management of finishes and peculiarities; - Use of elements in the model; - Integration with the estimation system CPI – Concrete Plant International – 1 | 2013
Rapid Planetary Mixer 0.375m3 - 3m3
Rapid Pan Mixer 0.5m3 - 4m3
Rapid Twin Shaft Mixer 1.7m3, 3m3 & 4m3
Rapid International Ltd Tel: Email:
+44 (0) 28 38840 671
[email protected]
www.rapidinternational.com
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 36
NEWS RULES could determine the costs for machining cycles, formwork operation including cleaning and preparation, storage, material volumes, geometric characteristics, number of identical pieces, etc.
Fig. 3: Examples of drawings for estimation
Fig. 4: Cost Rules and Client Offer
Estimation and cost analysis To easily and safely incorporate the elements that make up the project, it is important to develop the calculation directly from the architectural design (structures, roofing, sealing, foundations, windows, etc.) to provide the customer with the corresponding offer and, if necessary, speedy modifications of the same. At this point, it is necessary to study the cost of each item involved in the project. This is traditionally done with the help of a price list indicating a price in linear, area, or volume terms and any such assessment will be based on typical averages of previous production runs. This method (averaging) enables the company presenting the quotation to the cus36
CPI – Concrete Plant International – 1 | 2013
tomer to offer lower costs for complex jobs and higher cost values for simple jobs or highly repetitive ones rather than running the risk of acquiring complex jobs at the price of simple ones. Also, in addition to a cost analysis, it is possible to assess the materials (concrete, reinforcement, lifting, processing, and special) necessary for optimal and accurate machining cycles and production tooling. If, for instance, a project featuring a vast number of artefacts (numerous different pillars, different buffer solutions with various joints and colorations) is at stake, this will entail an evaluation of the time periods needed for changes in dimensioning or the preparation of the formwork needed. Another programme feature entitled COST
As for transport, it is interesting to perform a simulation of loads, using a listing of regularly available vehicles. For installation jobs, it is useful to develop a sample assessment day including all expected jobs on a workday, floor, or area basis, including buffer periods for unexpected interruptions. In this way, possible errors inherent in manual calculation are avoided since all necessary information is available in the drawings, and provided to the customer. All these data is depicted in the offer and can be processed in the drawings themselves to instantly and automatically generate a modified offer, if needed. This procedure will substantially reduce the error margin in the calculation of costs and will help decide as to whether a project should be accepted or not.
Structural calculation For the structural calculation according to European and international standards, it is necessary to employ software that helps the designer to decide which type of structural analysis (linear, nonlinear, static, dynamic...) better fits the structural model to be realized. For this purpose, it is essential considering the complexity of some models - to maintain a close collaboration between the software vendor and the designer to make better use of the flexibility of the tool regarding the choices to be made in order to avoid misapplications. If it is impossible to create a "black box" within the architectural project that will allow the executives to exit the system automatically in case of need, then the goal must be to automate all downstream procedures as much as possible in accordance with the choices made by the designer, and this is true for the modelling of structures just the same as for the dimensioning and design of the structural elements. By means of specific software, it is possible to start from an architectural design to develop a three-dimensional frame structure besides calculating the weights of its individual components, and, in relation to the geometrical and mechanical project characteristics, ending up in evaluating the corresponding actions on account of permanent load impacts that the structural elements are directly subjected to.
www.cpi-worldwide.com
AZ
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 38
NEWS
Fig. 6: Connection details
The main features of a specific software that is distinguished from other so-called generic tools will focus on and address the needs of the precast industry and the structural requirements that this industry has to deal with. Three different advantages of any such software can be highlighted: -
-
Fig. 5a-c: Architectural model/scheme and calculation analysis/construction site
-
38
CPI – Concrete Plant International – 1 | 2013
The possibility of “overlaying” the mere calculation model in order to verify the design directly and in a simple fashion and to identify any modelling errors or inaccuracies. An "automatic" switch from threedimensional drawings to three-dimensional finite element models; any such transition would be rapid and without those errors and inconsistencies that are often encountered when working with outlines of buildings using complicated generic software programmes High precision in the finite element model in terms of structural details typical of precast buildings (e. g eccentricity due to protrusions, due to non-symmetric beam and column supports, etc.).
-
-
-
-
Automatic check of groups for the homogeneity of structural elements; this possibility is, as a matter of fact, generally useful in construction, however, absolutely essential in the case of prefabrication as the production of such identical elements will have both technological and price advantages The possibility of integrating test runs on particular elements such as prestressed beams or roof tiles directly into the calculation module The possibility of interacting with other software and management tools related to the calculation of the precast structure Complete customization of the calculation settings is present even if there exist certain default settings for the regular standards.
Fastening connections Within the scope of precast structures, fasteners take on an important job as it is these companies that are responsible for the connections between the various structural elements that constitute the building. These connections, which are subject to both verwww.cpi-worldwide.com
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 39
NEWS tical and horizontal action such as weight, wind and possibly occurring seismic events, must be designed so as to ensure the toleration and transmission of all such stress agents, preventing sagging or other negative influences not foreseen during designing. After the initial phase of architectural design, a designer will hence define the type of connections to be used along with their inserts (boxes, profiles, kits, etc..) with respect to the various elements, taking into account the regulatory requirements of the companies as well as verifying the distances from the edges of elements, the flow rates in the case of suspensions, any interferences in the case of multiple inserts. The provision and maintenance of an efficient and thoroughly developed library specific for precast will allow the designer to quickly choose the desired type of connection and verify its proper functioning. Once the type of connection has been chosen, the next part of the project will consist of precise step-by-step instructions pertaining to the position and the way that the chosen elements are installed along with the connections. Any change in the position of
the connecting interface will have an effect on the total architectural design and will result in an update of insert positioning of the structural elements. A supporting feature like this will not require any indication of units or dimensions, because the positions of the inserts are tied to the functions developed for each type of constraint, causing a drastic reduction of errors and the automatic calculation of the inserts will leave more room for more creative designing aspects of the project.
Working drawings, shop drawings Having thus completed the three-dimensional model of the building (architectural model including fastenings), the system will now be able to identify all the elements and their variations (dimensions, sizes, inserts present, etc…) and assign a code to each of them. It will also update assembly tables, process production boards by means of a table and the necessary structural reinforcement, and provide all the calculations for the materials used within the project. The automatic design process as described above will allow the development of in-
creasingly homogeneous production boards, regardless of the designer who has developed them. To support the designing activities, a standardized and rigidly observed procedure must be developed that describes the fashion in which consultations are held in both technical offices and production.
Production planning To further support the activities necessary for implementing orders, it is useful to have a medium and long-term planning system that constantly maintains an overview of all company activities, setting priorities for the implementation of orders in terms of technical office jobs, production capacities, transport and assembly. Any such planning will involve the following: • All already designed orders: These are orders to be produced in whole or in part, in the latter case only the artefacts to be produced will be evaluated; • All orders they have not yet been designed: The artefacts related to
BAUMA STAND
1002/2 IN OPEN AIR AREA
NEW — launched in
BAUMA
COBRA COBRA concrete concrete mixing plan plantt Containerized concrete Containerized concrete mixing plan plantt tt CBUDITJ[F CBUDITJ[F1,0 - 3,0 m tt UUXJOTIBGUPSQMBOFUBSZNJYFS XJOTIBGUPSQMBOFUBSZNJYFS tt TVJUBCMFGPSSFBEZNJYBOEFMFNFOUGBDUPSZBQQMJDBUJPOT TVJUBCMFGPSSFBEZNJYBOEFMFNFOUGBDUPSZBQQMJDBUJPOT tt 5IFNPTUBDDVSBUFBHHSFHBUFXFJHIUJOHTZTUFN 5IFNPTUBDDVSBUFBHHSFHBUFXFJHIUJOHTZTUFN “ON O THE FLY”
Tec e will Oy Rahtikatu 3 B, 80100 Joensuu, FINLAND Тelephone. +358-10-830 29 11 | inffo@ o@t o ecwill.com
tt .PCJMFBOETUBUJPOBSZDPODSFUFNJYJOHQMBOU .PCJMFBOETUBUJPOBSZDPODSFUFNJYJOHQMBOU m /h with capacities of 40 - 160 m tt / /&8NPCJMFNPEFMXJUIDBQBDJUZPG &8NPCJMFNPEFMXJUIDBQBDJUZPG 160 m /h with 4,0 mCBUDITJ[F CBUDITJ[F tt 1BUFOUFETQFDJBMDPOTUSVDUJPO 1BUFOUFETQFDJBMDPOTUSVDUJPO tt .PCJMFGPVOEBUJPOJOUFHSBUFEUPNJYJOHQMBOU .PCJMFGPVOEBUJPOJOUFHSBUFEUPNJYJOHQMBOU tt 5IFNPTU 5IFNPTUBDDVSBUFBHHSFHBUFXFJHIUJOHTZTUFN BHHSFHBUFXFJHIUJOHTZTUFN“ON THE FLY” 8JOUFSNPEFMXJUI8JMM$PO)PUIPUDPODSFUFQSPEVDUJPO tt 8JOUFSNPEFMXJUI8JMM$PO)PUIPUDPODSFUFQSPEVDUJPO
WWW.TECWILL.C COM OM
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 40
NEWS
Fig. 7: General management control flow
these orders are already associated with all the dimensional information for their placement; • All the estimates in the acquisition phase: also in this case, all the information necessary is present in production planning.
Order management Having collected all relevant data, it will then be easy to organize both the economic control of every single order and the control of the overall production cycle or for individual production lines. The virtual test runs to be performed concern the quantities and amounts in the development phase of a project’s budget and the recalculated values obtained in the course of actual production to arrive at the resulting balance sheet data which will allow you to detect material consumption inadequacies and readjust the cost.
Considerations before setting up a software system Before considering the inclusion of any such system within a company, it will be necessary to determine the main reasons that call for any such implementation. This could be, for instance: a) The need to organize company activities by means of an integrated system permitting an exchange of all relevant information to all departments concerned: sales, technical, production, purchasing and administration; b) It is desired to provide the customer 40
CPI – Concrete Plant International – 1 | 2013
with quick answers to inquiries and to accurately react to customer requests, both for new estimates and variations of old ones; c) It is desired to measure productivity in the various individual departments, to learn about critical issues and to develop a working structure based not only on the goodwill of people but on expert knowledge of how a system of this nature would improve the company’s organization d) It is “teamwork” that should be the target of system implementation: all employees are important, but everyone can do without the other as well.
Evaluating the strengths of an integrated system a) An integrated system will allow any authorized member of staff to access and/or edit information and make the new data available to all colleagues. For example, if an architectural design is changed, say, by changing the length of a beam, the system will, in addition to automatically updating all the drawings, also update all calculations, BOM parameter values, production boards for the building in question along with calculations of weight, volume, lifting hooks, production scheduling, etc.., b) The entire company management, automation processes, and "knowhow" are handled by the system: design, cost, business proceedings, production standards, etc. are avail-
able to all relevant users c) There are no more “data islands” in the company (usually on Excel spreadsheets) that often do not match those of other “islands”.
System weaknesses a) The most critical aspect when implementing the system is personnel. To combat this, meetings must be held at regular intervals, especially when new staff is employed.
Customer relations a) After a general project outline, it is necessary for the customer to indicate his overall intentions, and on this basis a project is prepared to achieve the desired objectives; b) To implement the system, a general agreement must exist between the involved heads of departments, i. e. management must share the view that using the system is of advantage to project performance. c) Training is useful, however, on top of this, all users must be convinced of the need for changes in working tools and the advantages that exist in using them.
Return on investment Due to the drastic reduction of errors and inefficiencies that can be arrived at by means of the automated checks and validations required in the different project phaswww.cpi-worldwide.com
02-news_16-43_en_Layout 1 16.01.13 11:15 Seite 41
NEWS es, the investment into this system will pay for itself in a short time (i. e. within one to two years). In summary, the advantages for companies implementing this design and integrated management system are as follows: a) The project developed by the sales department can be used as a basis to further process the quotation by the technical department to obtain a final confirmation of the order; b) The order design can reveal the data for order management and an automatic comparison between estimation and order design can be obtained; often at this stage there is still some scope for negotiation or "calibration"; c) The connections between the various artefacts (structural panels, beams, columns, tee-beams, etc..) can be positioned, thus executing a control of congruence (comparing dimensions, tolerances, load flow rates, etc..) and placing all the connection inserts appropriately without the need of any additional measurement entries; d) The system is able to recognize the differences in geometry and inserts and determine the entire manual work to be performed - and then develop shop and working drawings; e) Based on the standardization of the drawings, all the working drawings are automatically produced for the various components; f) All necessary data for the production plan and procurement of required materials (concrete, inserts, mounting kits, etc...) is available g) All drawings produced are made up the same way, regardless of who carried out the project part, and therefore production will always have access to the same information; h) With the development of columns, beams, regular panels, curved panels, slabs, and all reinforcement designed automatically by the calculation modules, there will be a drastic reduction of design time and a reduction in errors.
Baltic Tiles, St. Petersburg, Russia
COMPLETE CONCRETE BATCHING PLANTS - WITH HUNDRED YEARS’ EXPERIENCE FROM THOUSANDS OF PLANTS INSTALLED WORLDWIDE
Conclusion In this article, different aspects have been analyzed regarding the demands and expectations of a precast manufacturing company as regards a system (made up by software and supplier system knowhow). According to experience gathered by the author, it can be said that, from a theoretical point of view, any such system will markedly improve project handling. However, an absolutely essential prerequisite for such improvement will be that all individuals involved will have to change their attitudes to a substantial degree – and this is likely to be one of the gravest obstacles to success. In a favourable economic environment, the overall business performance of a company may be satisfactory. However, when a market turns out to become less attractive for a company’s activities, annual budgets - and returns - will call for more stringent management to compensate for lower margin contracts in the annual balance sheet. When this is the case, it becomes essential to precisely know the cost of each and every contract with the least possible margin of error, so that a decision can be made as to whether the project is acquired or not. With a standardized design system, technical departments will also be facing changes and challenges. Basically, all company activities will pass over from “craftsman” projects, where results are essentially based on the capabilities and experience of every single technician, to an “industrialized” project process respecting the “company project manual”. It is then at the very beginning of a project study where “senior” technicians will make use of their capabilities and www.cpi-worldwide.com
CPI – Concrete Plant International – 1 | 2013
Gulf Cement Industries, Al Ain, UAE
Come and meet SKAKO CONCRETE in Munich – Hall C1, booth 135/236
www.skako.com
02-news_16-43_en_Layout 1 16.01.13 11:16 Seite 42
NEWS experience to contribute the most part of their expertise; this will allow to carefully evaluate the costs before the project is forwarded to “junior” technicians who will then execute it with the help of the relevant software support. In this way, a company will have a greater amount of time to invest its know-how into the first phase of the project and will also be able to plan its own production plant utilization. Furthermore, all company graphics, calculation links and evaluations will be standardized and independent of individual project managers. In the end, all conventions and project algorithms featured in technical company manual will be mirrored and established in the implemented system. 왎
FURTHER INFORMATION
CSG Information Technology S.a.s Fiorenzuola d’Arda (PC), Italy T +39 523981374
[email protected], www.csgit.it
Fig. 8a-c: Control (materials, quality, stock, transport) using barcode cards
42
CPI – Concrete Plant International – 1 | 2013
Emporio do Premoldado São Paulo, Brazil T +55 11 81628822
[email protected] www.emporiodopremoldado.com.br www.cpi-worldwide.com
