BubbleDeck

The biaxial hollow deck

Basic Principle
Reinforcing mesh, top
Air bubble (hollow ball)
made of (recycled) plastic
Reinforcing mesh, bottom

BubbleDeck Reinforcement module

(Product Type 1)

BubbleDeck Semiprecast panel

(Product Type 2)

Key benefits of the BD system

The keywords of construction in the future is

Faster construction time

Greater flexibility
Better environment
And as a result - better total economy achieved by the use of the BubbleDeck system

Helsfyr, Norwa

Harpa (Iceland) by Henning Larsen Architects

Winner of Mies van der Rohe Award 2013

Advantages

Economy

Savings in materials are substantial (up to 50 %)

Transportation costs are substantially reduced

Faster construction time (reduction in erection cycles with 20-40 %)

Subsequent work (installations), is simplified

Buildings can be made more flexible; changes are much less costly

Lifespan of buildings are longer

Advantages

Environment

Less material consumption - cement, aggregates, water, steel

1 kg of plastic replaces 100 kg of concrete

Less energy consumption - in production, transport and carrying out

Less emission - Savings in CO2 emission up to 40 kg / m2

No waste generation - every component can be recycled

Advantages

Design

The main structural consequences with BubbleDeck are:

Reduced weight
Increased strength
Larger spans
Fewer columns
No beams or ribs under the ceiling
Pillars have no capital

Superior Architectural Design

Free choice of shape
Large overhang
Larger spans / deck areas
No beams and fewer columns results in flexibility
Areas as not needed can simply be cut out
Interior design can easily be altered

Large Cantilever at City Hall in Glostrup, Denmark

Large Cantilever at City Hall in Glostrup, Denmark

Walterbos Complex Tax Office Towers

Car Parks No Beams or Downstands

[ Retail Roermond

Car Parks No Beams or Downstands

[ Concerthouse, Iceland]

Car Parks No Beams or Downstands

[ Concerthouse, Iceland]

Roof construction of Town Library of Almere/NL

Fast & Simple Production

BubbleDeck Reinforcement modules

(Product Type 1

1.Place bottom mesh on table

2.Place and weld lattice girders on bottom mesh
3.Bag with correct number of balls can now be emptied above bottom
Girders help in separating the balls. Balls will fit into every second
4. Place top mesh above lattice girders (and balls), fix/weld top mesh

BubbleDeck Semi precast panels

5.
6.
7.
8.
9.
10.

(Product Type 2)

Pour concrete on formwork table

Place spacers on concrete (to secure correct concrete cover)
Place BubbleDeck Reinforcement module into the concrete
Place temporary counterweight (concrete beam) above module
Vibrate
Panel can be removed next morning

2. Welding Lattice girders to bottom mesh

3. Placing balls

4. Fixing top mesh

Finished BubbleDeck Reinforcement module

One BD module per 30 minutes for 2-3 workers

5. Preparing concrete bottom

7. Placing BubbleDeck Module into concrete

10. Finished BubbleDeck Semiprecast panel

Fast implementation

Prefabricated BD reinforcement modules/panels

Fast placement of modules/panels onsite

High uniform quality

Made to measure
Shear reinforcement etc incorporated

For BD reinforcement modules, one crane can place 10 - 15 modules p/h

For BD semi precast panels, one crane can place 6 - 12 panels per hour

Limited and simple onsite reinforcement

Joint splice bars placed simultaneous with modules

Easy walking and working platform
Normal erection cycles of 4-5 days. Speedy cyclus 3 days

Fast & Simple Execution

1. Place temporary supports

(if BD modules: 2. Place horizontal formwork )
3. Place BD Reinforcement modules / panels
4. Place splice bars across joints
5. Place hogging steel (shear steel already integrated in pr
6. Perimeter steel and edge scaffolding
(if BD modules: 7. pour first concrete layer: 5 to 10 cm; wa
8. Final concreting of slab

1. Temporary supports

BD Modules on traditional formwork (Product Type 1)

BD semi precast panels (Product Type 2)

4. Splice bars across joints (placed simultaneous with modules/panels)

5. Steel above columns for hogging moment

8. Concreting

(no need for adjustment layer)

Simplfied finishes, as beamless ceiling is of high quality

Finalizing facades

Fast implementation

Fast placement of modules/panels onsite

Average size of BD modules/panels: 20 m2

Time to install one module/panel:
5-8 min
Capacity per crane:
140 240 m2 / hour

Limited and simple onsite reinforcement

Joint splice bars placed simultaneous with modules

Limited onsite steel, as major part can be preinstalled in BD
modules/panels
Easy walking and working platform; easy concreting
Limited amount of workers
Normal erection cycles of 4-5 days. Speedy cyclus 3 days

Productivity Temporary supports

oManpower:
o
o
o
o

06
04
01
01

assemblers
helpers
crane signaler
supervisor

o Productivity =< 2,000

m/day
250 m/hour

o Indices:
o Assemblers
= 0.0241
MH/m
o Helpers
=
0.0160 MH/m
o Signaler
=
0.0040 MH/m
o Supervisor
= 0.0040
MH/m

Productivity Slab
o Edge Formwork: Productivity = 35.84
m/day
o 02 carpenters
o 02 helpers
o 01 supervisor
o Onsite Reinforcement: Productivity =
5,632.00 Kg/day
o 06 steel workers
o 03 helpers
o 01 supervisor
o Onsite Concrete: Productivity = 143.36
m/day
o 03 masons
o 07 helpers
o 01 supervisor

o Indices:
o Carpenters = 0.4464
MH/m
o Helpers
= 0.4464
MH/m
o Supervisor = 0.2232
MH/m
o Indices:
o Steel workers = 0.0085
MH/Kg
o Helpers
= 0.0042
MH/Kg
o Supervisor
= 0.0014
MH/Kg
o Indices:
o Masons
= 0.1674
MH/m
o Helpers
= 0.3906
MH/m
o

April 2011

Hickory Developments has again chosen the BubbleDeck system - this time for
Alt at Travancore. Faced with 26 levels each of over 1,500 square meters to
build, project manager Peter Frank said:
"BubbleDeck was a clear choice due to the fast floor cycles achievable,
yielding a substantial saving in the program at a competitive price ".

Implementation of the BD system

Standard cycle of 4 days

(temporary supports not included)

Implementation of the BD system

Fast cycle of 3 days

(temporary supports not included)

Large BubbleDeck Semiprecast panels

11 x 7 m

BUBBLEDECK SYSTEM

BUILD MORE WITH LESS