The use of plastic balls can reduce the use of concrete slabs by up to 30%, while reducing carbon dioxide emissions and using fewer building materials for the purpose of sustainability in the construction industry. Plastic balls using recycled materials, environmentally friendly and durable, the cost and concrete is not far away, there are many countries in use.
Plastic Balls In Floor Slabs
Plastic ball floor slab is a revolution and innovation in the construction process, this technology is in the non-load-bearing slab on the use of recycled plastic balls for filling, thus directly reducing the use of concrete, but also reduce the weight of the structure, extending the life of the building. By combining recycled plastic, the span of the structural columns can be extended by 50 per cent, while the panels connect the concrete structure in both directions, eliminating the need for beams, with the following general features.
- No design restrictions, flexible and changeable forms can be adapted to various forms of building structures.
- reduced deadweight, the reduction of deadweight greatly saves the cost of building foundations.
- increasing the span between the columns by 50% over traditional structures.
- eliminating the cross-beam structure, making the construction process faster and more economical.
- Reduce the use of concrete, 1kg of recycled plastic can replace 100kg of concrete.
- energy saving and low-carbon, reducing carbon emissions.
Plastic ball floor slab for nearly a decade in Europe has been successfully applied to a variety of building construction among them. In Denmark and the Netherlands have more than one million square meters of multi-storey buildings using this system.
The installation process can be simply divided into the following processes.
- Temporary pre-installation support with horizontal beam support at 1.8 m and 2.4 m spaces for placement.
- placing the structure and placing the semi-finished components in place.
- the upper layer is laid, and after installing the bottom fixing device, the upper layer ties the mesh structure to connect each component.
- shear reinforcement, with reinforcements installed between the columns.
- Side reinforcement, installation of side reinforcement devices.
- the installation of pouring devices, the installation of pouring bearing on the existing concrete and fixing to the top of the horizontal mesh structure.
- Treatment of pouring apparatus by placing polymeric plate supports between members and between columns constructed on top of each other.
- Prepare before pouring, seal the gaps between components, clean and moisten the original concrete.
- Pouring, filling concrete, vibration, maximum capacity 10mm higher.
- Work after pouring and remove unwanted structures in 3 to 5 days.
Different building configurations make for different structural requirements, and plastic ball floor systems take different solutions depending on the structure, as shown in the following diagram.
The system can be applied in three different scenarios.
Option A: Seiko elements, this option has 70mm of precast concrete at the bottom of the three layers of elements as a permanent structure, but this saves the use of precast load bearing mouldings, the elements are placed directly on temporary supports, the joints are pre-reinforced with shear and edge reinforcement, then the side mouldings are installed, and finally the cover is cast.
This structure is ideal for new construction, but requires the cooperation of a crane.
Option B: prefabricated formwork, this structure is placed directly on the traditional structure, then pre-stressed, and in the second step cast directly into the slab. It is suitable for the renovation and retrofitting of buildings.
Option C: Wooden elements, which are installed directly into the building after fabrication and are only used in non-load-bearing structures.
This solution has been used in many projects, such as the 32,000 m2 Media City, the Millennium Tower, and the offices of the City Hall, where it has shortened the construction period and allowed greater flexibility in the design of the project.
Summary Of Benefits
The green energy saving benchmark, which saves a lot of concrete during the construction process thanks to the sandwich structure, saves for every 5000 m2 of plastic ball floor slab: 1000 m3 of concrete, 166 truck trips, 1798 tons of foundation load or 19 piles, 1745 GJ of energy for the production of concrete, 278 tons of CO2 emissions!
If you want to know more about the concrete & construction technology, please check: Concrete Blog