Conference 2011
Let’s Construct Europe’s Future
With Innovative Buildings and Infrastructures
Construction and Societal Challenges
Conference under the patronage of the Polish National Contact Point for Research Programmes of the EU
Supported by:
Radisson Blu Centrum Hotel - WARSAW
04 / 05 October 2011
„New
New Industrialised Construction Process for
transport infrastructures based on polymer
composite components”
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ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Previous experiences
First European FRP vehicular bridges:
ƒ Pumacon bridge (Spain 2004)
ƒ HP FutureBridge M111 bridge (Spain 2008)
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Manual process
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Installation – manual/semi manual
ƒ Beam-deck system
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Result of the manual process
Conclusions:
• FRP bridges can be manufactured manually.
manually
• FRP bridges manufactured manually are not
economically competitive comparing to those
made in steel or in concrete.
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Economical study
Cost study:
ƒ labour
ƒ material
ƒ energy
ƒ manufacturing
ƒ transport
ƒ assembly
Conclusions:
• Automating the process will make the
product cheaper and more competitive.
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Next step
Trans-IND
„New Industrialised Construction Process for
transport infrastructures based on polymer
composite components”
Starting date
1st June 2009
Duration
4 years
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Trans-IND Consortium
20 partners (9 countries)
ƒ 6 large companies
ƒ 6 High-Tech
High Tech SME
SME’ss
ƒ 8 Research organizations
Research:
Industry:
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND objectives
Thee main
a object
objectivee iss to de
develop
e op a cost
cost-effective
e ect e
integrated construction process that will enable
the maximum capability of industrialisation
of components
p
for transport
p infrastructures
using FRP composite materials.
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND detailed objectives
Innovative conceptual model for composite
p
coveringg amongg others:
components
ƒ material engineering and components design
ƒ off-site
ff it manufacturing
f t i ffacilities
iliti andd processes
ƒ intelligent
te ge t logistics
og st cs
ƒ on-site assembly and disassembly
ƒ procurement (public and private)
ƒ knowledge management
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Trans-IND detailed objectives
ƒ Catalogue of FRP road infrastructure elements and
qquick pplug-in
g jjoint solutions between them.
ƒ Off-site industrialisation process based on
Innovative machinery,
machinery ICT tools and robotics
robotics.
ƒ On-site assembly methods based on RFID,
intelligent positioning systems, ICT’s
and robotics.
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Trans-IND detailed objectives
ƒ Software platform for holistic management, design,
g
simulation,, visualization and knowledge
management of the process.
ƒ Recommendations for standardisation
of FRP components.
ƒ Demonstration of the flexible industrialisation
system through real scale bridge build up.
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND catallogue
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND components
Open-shaped beam
Close-shaped beam
After the
Aft
th
conceptual study
Span: 9-18 m
U-shaped beam
Span: 15 – 30 m
Main
materials:
-Glass
Glass fiber
-Carbon fiber
Span: 25 - 45 m
-Epoxy resin
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
Public
Trans-IND bridge concept I
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND elements
Safetyy barriers
Deck solution
Acoustic barriers
JOINTS
Acoustic barriers
Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Trans-IND Production
Beam manufacturing
ƒ Filament winding process
ƒ Automated type Placement
Deck, Safety Barriers, Acoustic Barriers
ƒ Pultrusion process
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Morphological control
Scan
Process
3D representation of the Scanning System
on a open shaped beam mould
Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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Public
Morphological control
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Paweł Poneta, ECTP-E2BA-Eracobuild Conference 2011 Warsaw - 4 & 5 October 2011
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CONTENTS:
www.transwww transwww.trans
trans - ind.eu
ind eu
Paweł Poneta
Project Coordinator
Mostostal Warszawa S.A.
Public
p.poneta@mostostal.waw.pl
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