iTWO WORLD 2018

Sustainable Technology for Modular Construction and Prefabrication

Dipl. Ing. Anne Jacobs

Head, Industry Team Construction Asia Pacific

BASF – we create chemistry

Our chemistry is used in almost all industries

We combine economic success, social responsibility and environmental protection

Sales 2017: €64,457 million

EBIT 2017: €8,522 million

Employees (as of December 31, 2017): 115,490

6 Verbund sites and 347 other production sites

Over 10,000 employees for R&D with over 1,000 based in Asia Pacific

regional D

global R

global D

Chigasaki(Admixtures)

Research and Innovation in Construction Chemicals

Chigasaki

Shanghai

We innovate to create value throughout

the life cycle of buildings

Construction phase

Higher productivity, faster progress, lower overall costs,

lower consumption of natural resources,

better energy efficiency,

improved health protection & safety

Use phase

Extended service life, lower life cycle costs,

better performance and functionality,

improved safety & comfort

Research and innovation enabling sustainable construction

-5.9

9.3 °C

-4

-2

0

2

4

6

8

FLIR Systems

Environmental Challenges for the Construction Industry

Causes

10 %of the world’s

emission of fine

dust

Contributes to

30 %

of the global

greenhouse

gas emissions

Concrete: most widely used

man-made material

(1m3 /Pers/annum)

Consumes up to

40 %of the worlds

energy

The Construction Chemicals Portfolio

Wall Systems / EIFSTile Fixing Systems

Flooring SystemsPerformance

GroutsWaterproofing &

Sealants

Expansion Control Systems

Cement AdditivesUnderground Construction

Concrete Repair & Protection Systems

Admixtures

Solutions for Flooring

Heavy Duty Flooring

Food Industry Flooring

Industrial, residential and

commercial flooring

Highly durable

Fast and easy application

Low maintenance

Food and beverages safety

Installing heavy-duty floors faster

09.11.20188

Ucrete® Fast – is a new version of heavy-duty Ucrete industrial floors

with installation time reduced from 48 hrs to less than 12 hrs

Innovation to strengthen leading position

Ucrete® industrial flooring solutions have been offering market leading performance for over 40 years

Speed of installation is a key recent market requirement esp. in the food industry

The fast cure cycles are enabled by new solutions for ensuring reaction stability and ways of maintaining sufficient open time to install the material

Advantages

Recycled supplementary cementitious materials (fly ash, slag), non-cementitious fillers

Installation in working factories esp. in the food industry without production downtime,

e.g. overnight

Same chemical and physical properties as the standard material when cured

MasterTop 1327-20dB:

Resin flooring system that combines design with noise reduction

“There is basically no

comparison to any

other flooring system.”

Tom Haarsaker,

Manager, Minor Industriplast AS

Quantified Sustainable Benefits

7% Lower

life cycle costs

20 dBReduced

impact noise

50

yearsExpected

service life

Solutions for Cement: Additives

Grinding Aids

Performance Enhancer

Lower cost, higher efficiency and

high quality of cement

production

Reduction of CO2 emissions

Green Sense Concrete

Smart Dynamic Concrete

Optimization

Plasticizer

Fibers

Faster production

Enhanced properties (strength,

durability, cost, workability,..)

Reducing CO2

Solutions for High Performance Concrete: Admixtures

Fiber reinforced concrete optimisation for easier placing and

performing solutions

MasterFiber® is the BASF fiber range developed for concrete

reinforcement

Synthetic fibres with optimized chemical composition and surface

properties to provide:

better dispersion,

easier concrete handling

higher bond to the concrete matrix

for improved ductility.

Advantages

Final concrete properties like cracking behaviour, corrosion are

enhanced.

Possibility to reduce the concrete thickness

Substitution of steel mesh

Sustainable alternative to steel reinforcement

“MasterFiber has

enabled us to save both

production time and

materials.”

Abel Medel,

Technical Manager at Uniblok, Toledo

Quantified Sustainable Benefits

Using MasterFiber, Uniblok achieved significant Quantified Sustainable Benefits. The

facts:

10%MORE EFFICIENT

PRODUCTION PROCESSES

The amount of steel is limited to the

technical optimum using the existing steel

mesh section and the complementary

contribution of PP fibers in tensile strength

and crack width reduction. This saves

steel and energy. Less steel saves time

and money.

LOWER GLOBAL

WARMING POTENTIAL

Less steel weight significantly reduces

CO2 emissions. Similar benefit can be

observed for the other environmental

impact categories like POCP

(Photochemical Ozone Creation

Potential), AP (Acidification Potential)

and Total Resource Depletion, which are

all reduced between 20% and 25%.

LESS STEEL

BY WEIGHT

Up to 20% less steel is needed

while providing the required

strength properties with improved

crack behavior.

20% 21%10% More

efficient production

processes

20%Less

steel by weight

21% Lower

Global Warming

Potential (GWP)

What is Green Sense® Concrete?

09.11.201816

The Green Sense® Concrete technology offers a unique performance

package that optimizes concrete mixtures with regard to environmental

friendliness, performance and production costs.

Our solutions: MasterGlenium®

Advantages

Formulations of concrete mixtures that contain a high proportion of

recycled materials

Decrease of carbon footprint and environmental impact of buildings

Extended lifecycles of buildings

6% of the worlds CO2 emissions are released from the cement

production. Alternative Materials for Concrete Reduce this Impact.

Alternative fines

Fly ash

By-product from coal power production

Slag

By-product from steel* production

Aggregate fines

By-product from aggregate production

Locally sources alternative materials

Can be added to concrete in controlled amounts to

reduce the cement content and improve some properties

of the concrete.

Alternative Pozzolans Alternative powders

Can be used in the right combinations to reduce

concrete CO2 volume and improve desired

properties.

Green Sense Concrete: No Trade Off! It is Possible to Meet the

Projects Needs and Accreditation Requirements

Smart Dynamic Concrete Ultra High Strength Concrete Architectural Finish

High Durability Extreme Pumping Long workability times

SmallSmall

Large

Compressive strengths

> 120MPa

Low fines (<380kg/m3) SCC

Flow:

580 – 650mm

Superior

colors and

surface

finish.

No

remedial

work

Designing

concrete to

be pumped to

extreme

vertical

heights or

long

distances

Slump

retention

tailored for the

project needs

and

environmental

conditions

Meeting &

Exceeding durability

Life Cycle Analyzer (Tool)

Assess sustainability impact of concrete (for certifications like LEED)

Real-time calculation of different concrete mix-designs

Tailor-made LCA

Fast

Facts

Envir

onm

enta

l Im

pact

Project Reference: One World Trade Center, NYC

Project Overview, GOLD LEED

• 135,000 m3 of Green Sense Concrete

• Developer: Port Authority of NYC & NJ

• Architect: Skidmore Ownings

• Structural Engineer: WSP

• Contractor: Tishman Construction

• Total construction cost: 3.9 bn USD

• Height: 541 m

• 3 billion Litres of Water saved

• 8 Million KWs of Energy saved

• 5445 tons of CO2 saved

• 340 tonnes of Fossil Fuel Savings

Sustainable Solutions:

Accelerating Concrete Hardening

Master X-Seed® -

BASF’s unique patented hardening accelerator speeds up concrete hardening 2 to10 times

at early ages (6-12h)

▪ Accelerates construction in Ready-Mix Concrete

Concrete framing with short production cycles

Faster setting time enables use of power trowels on concrete slabs at a reasonable

short time

High early and 16h strength in winter conditions

▪ High quality concrete

Increased strength development leads to improved safety and predictability of the final

concrete

▪ Material optimization, reduction of CO2 emissions

Highest flexibility in using composite cements and SCM

Admixture solution for sustainable concrete hardening

“In the precast industry,

it is all about

minimizing

the demolding times!”

Thomas Beike,

Managing Director fdu Betonwerke

Quantified Sustainable Benefits

Using the revolutionary admixture Master X-Seed, fdu Betonwerke achieved significant Quantified Sustainable

Benefits, in many of its plants, including:

50%FASTER CONCRETE

HARDENING

Master X-Seed boosts the

hardening process. This leads to

shortened demolding times. Output

of existing plant facilities can

significantly be increased.

REDUCED CO2

FOOTPRINT

A reduction of the CO2

footprint can be achieved

by binder optimization.

LOWER ENERGY

COSTS

High early strength is achieved at

low ambient and heat curing

temperatures reducing the need for

energy intensive supplementary

heating of the molds.

15% 10%

10% Reduced

CO2 footprint

15% Lower

energy costs

50% Faster

concrete hardening

Wall/ Ceiling Systems

Thin

Light-weight

Long Durability

Energy-efficient

Off-site production

Concrete composite elements

Modular Construction Manufacturers need Reliable Materials and

Professional Support for Whole Building Solutions.

Our advantage:

Designed to be lightweight & high

performance

Advantages in acoustic and thermal

mass

Fast production, efficient lines

Modules can be piled up to 4 floors

First projects realized in Europe

BASF Materials

Admixtures

Insulation

Waterproofing

Flooring

Sealants

Grouts

Paints

Adhesives

…

Prefabricated Modular

Construction

Off-site prefabrication

Simple on-site mounting

Long Durability

Flexibility

Reusability

PVCC - Prefabricated Prefinished Volumetric Construction

Currently, we have Installed two Cubes for BASF Temporary Offices.

Our advantage:

Designed to be lightweight & high

performance

Advantages in acoustic and thermal

mass

Fast production, efficient lines

Modules can be piled up to 4 floors

First CPC object realized: hotel in CH

Early Strength Concrete for T301 Depot Buildings

Savings & Benefits Verified by BIM Simulation

Numbers of Columns (Cast-In-Situ) & Beams (Pre-Cast)

Rail and Bus Depot

6182 Columns (too big, too heavy for

precast)

21345 Beams (precast)

Original Plan

Required Strength to install the Pre-Cast

Beams on top of the Column = 40 MPa

In general, it will take about “7 days” …

Our proposal:

2-day early strength 40 MPa

Easy re-use of formwork, early placement

of beams

Cast

-In

-Situ

Column

Pre-Cast

Beam

The BIM Project Simulation is Showing Great Time Savings of Nearly

2 Month Construction Time in Total.

Original Planning:

January 2018

Updated Planning:

January 2018

Original Planning:

November 2018

Updated Planning:

November 2018

Updated Planning:

December 2022

Original Planning:

December 2022

Updated Planning:

December 2023

Original Planning:

December 2023

Original Planning:

Completion 15th Nov 2024

Updated Planning:

Completion 20th Sep 2024

BIM Simulation shows 4 weeks time saving (customer decided to use 3-day early strength instead of standard 7-day)

Pre-Cast Installation in Progress

THANK YOU