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 visitor The 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 pcs Shopdrawings 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

2. Floor and area 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 Formwork plan of 3200 signed column Formwork plan of 4000 signed 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

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 Reinforcement plan of 3200 signed column Reinforcement plan of 4000 signed beam Actually produced quantities: All reinforcement steel built into the elements: 875.720 kg All built-in steel parts and accessories: 6974 pc

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

The begining (2013 May – June) Placing and installing the precast structure (Engineering in the structural installation procedure) The begining (2013 May – June)

Middle time (2013 July – Augustus) Placing and installing the precast structure (Engineering in the structural installation procedure) Middle time (2013 July – Augustus)

Close to the end (2013 September – October) 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)

Precast is completed (2013 December) Placing and installing the precast structure (Engineering in the structural installation procedure) Precast is completed (2013 December) Thank you for your attention!