Introducing Ferrobeton Zrt. Hungary’s biggest prefabricator company

Established in 1955 in DunaújvárosProduce 60.000 m3 of concrete per year

FERROBETON is the member of the CRH Group and the middle-east european center of CRH Structural

Ferrobeton Zrt.’s fields of action

Design:Construction plan, shopdrawings, 3D modelling, statical calculations

Production:Structural products, railway elements, housing, road elements, electric poles

Transport: By road or railways

Installation:

- Possible to use higher quality of materials like C60/75 or higher- Controlled and monitored production, consistant quality- Independent from weather conditions- More precise production of reinforcement and concrete shape- Can be pre-scheduled for weeks, flexible in ordering

Basic about prefabricating concrete

Advantages Disdvantages

- Sometimes difficult to transport to site- Shape is often limited by the formwork capacity- Creating load-bearing joints are complicated and expensive- Unit cost is higher

Summary and worth to use

Recommended to use in complex structures where lots of same elements are repeatedRecommended to use to reduce in-situ concrete needs of large projectsRecommended to use to decrease construction time

Main projects of and their specifications

HANKOOK TYRE Factory 2006-2013 3 phases of 300.000 m2 total production areaNormal frame structure, one and 3 storey

GREEN HOUSE Building 2011-2012 3+7 storey office building with 18.000 m2 for officesCombination of columns, beams and hollowcore

GROUPAMA Football Stadium 2013 Stadium for more than 22.000 visitorsCombination of precast, monolitic and steel

HANKOOK TYRE Factory, Rácalmás 1st phase:

year 2006-2007

- Production area: 100.000 m2- Volume of precast structure: 7540 m3- Max. span of concrete beam: 26 m- Part of the roof structure is steel

2nd phase:

year 2009-2010

- Production area: 70.000 m2- Volume of precast structure: 5955 m3- Max. span of concrete beam: 32 m- No steel roof structure anymore

3rd phase:

year 2013-2014

- Production area: 100.000 m2- Volume of precast structure: 11385 m3- Max. span of concrete beam: 38,4 m- No steel roof structure anymore

HANKOOK TYRE Factory, Rácalmás

Structural description:- Foundation is solved with piling and in-situ base blocks- Column fixation is by precast rounded or doubled sockets

being concreted into the monolitic base blocks- Vertical bearing and stability by retangular columns with

the size of 50x50cm, longest column is 18,0m- Horizontal bearing by prestressed longitudinal I shaped

main beams and crossing secondary beams with T and I sections, longest beam is 38,40m

- Main groundfloor support is solved by TT floor panels above tunnels (calculated live load is 4 tons/m2)

The frame structure

Specification: the longest beam on roof has a span of 38,40 meters

Special multi-storey structural solution with precast elements

Structural description:- 3-storey building with the need of bearing 3 tons/m2 load- Column fixation is by precast rounded or doubled sockets

being concreted into the monolitic base blocks- Vertical bearing by retangular columns with the size of

60x60cm, longest column here is 21,0m (in one piece)- Horizontal bearing by beam grid in two direction, with

upside-down T shaped prestressed main beams and retangular secondary beams, longest beam is 12,0m

- 20cm floor plate is made with prestressed filigran panels with the thickness of 8cm and 12cm upper screed, max. span is 3,5m with no support

Specification: the highest column produced in one piece is 25,2 meters long

More construction pictures

GREEN HOUSE Office building, Budapest

Conditions to be known:- The erection time was scheduled to

winter time- The construction site was narrow, the

location is in the middle of the Capital- Only tower cranes were possible to use- 3 weeks was given to complete a floor- The span were between 4,50 and

13,2m- Only a few bracing cores were possible- There are 3 levels for parking in the

cellar as monolitic- There are 7 levels up for offices done as

precast

SPECIFICATIONS:- 7 levels of precast flooring- Octagonal shaped columns- Delta-beam for floor support- No column in one corner

Story: In Hungary almost all the office buildings are usually built with monolitic concrete structure sometimes combined with masonry. SKANSKA, a nord-european company insisted on that the structure has to be made by precast concrete elements to help FERROBETON completing this project.

GREEN HOUSE Office building, Budapest

- Usual sizes are 40/50 and 60/60cm- Most columns are 2-level high- All fixation is screwed by shoes- Beams are supported by consoles- Lightning protection is built-in- Beam ends are fixed with bolts- Some columns needed as circular - These were made as octagonal- Small, one level columns are 30/30- Weights were limited according to the capacity of tower cranes

Columns

GREEN HOUSE Office building, Budapest

- Side beams are retangular or L-shaped concrete beams- Inner floor beams are Delta-beams- Beams are supported by consoles- Beam ends are fixed with bolts- Weights were limited according to the capacity of tower cranes

Floor beams

GREEN HOUSE Office building, Budapest

- Long elements are FF 320 type- Short elements are FF 200 type- At bracing cores we used filigran floor plates- Floor elements are collaborating with 8cm of in-situ screed- Weights were limited according to the capacity of tower cranes

Floor beams

GREEN HOUSE Office building, Budapest More construction

pictures