1. 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

2. Difficulties of completing the precast concrete structure The stadium is for 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 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

3. 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

4. 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

5. 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

6. 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

7. 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: m3
Total quantity of all installed elements: pc
Shopdrawing quantity: 648 type of elements, formwork+reinforcement+accessories: pc

8. 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: kg
All built-in steel parts and accessories: pc

9. 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

10. 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

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

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

13. 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)

14. Placing and installing the precast structure (Engineering in the structural installation procedure)
Finishing (2013 November)

15. 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!