Nemetschek Scia’s solution for the precast industry is based on 3 major cornerstones.
Each of these solutions represents separate modules, which together form a fully integrated solution, ready to help you manage and optimize your company processes. All data is stored in one central database. The progress of the project and the individual precast parts are fully under control and managed.
Some examples:
- If a precast part is planned in production it will be blocked in the CAD system for making adaptations.
- The results of the structural analysis can directly be used in the CAD system for the automatic generation of reinforcement in slabs.
- The status of each element is visible on the screen (graphical).
- If a user is planning specific precast parts in e.g. the production, these parts are locked for other users.
- Equal elements are automatically recognized.
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The 3 cornerstones:: ► Design - Scia Engineer ► Detailing - Allplan Precast ► Production - PP Manager
1. Design: Scia Engineer |
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Scia Engineer is a 2D/3D structural analysis software for the analysis of all kinds of structures in concrete and prestressed concrete. This software is covering simple analysis but is also supporting complicated analysis with construction stages, non linear (cracking) concrete, time dependent analysis, dynamics etc.
For the precast industry we have very special features available for making your own parametric library with elements for fast design. We are supporting many international standards with of course also the latest Eurocodes.
Also special precast elements like Hollow-Core are supported. These specials are developed in close cooperation with the industry. For example, the Hollow-Core calculation according the Eurocode is done together with Echo Belgium, one of the biggest producers of Hollow-Core around the world.
► more about Scia Engineer |
2. Detailing: Allplan Precast |
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Allplan Precast is an extended development based on Allplan, one of the leading CAD programs for construction. The proven flexibility of Allplan is merged with a high level of automation, specifically developed for precast concrete elements.
The combination of this flexibility and automation results in a fast and accurate design of complex precast elements.
The workflow of Allplan is adapted to the most common processes in the precast industry in order to minimize implementation and adaptation efforts, and is developed to assist the precast companies in producing plans, production drawings and a Bill of Material for almost all kind of precast elements.
► more about Allplan Precast |
 Allplan Precast is an open system thus supporting most common exchange formats, used all around the world, like e.g. IFC, DWG, DXF, PDF, UNITECHNIK (for production plants), BVBS (for cutting and bending machines) and can be linked to ERP systems.
Examples of high automation:
- For slabs and walls there is an automated division of architectural floors and walls in precast elements including the automated generation of reinforcement, lifting bolts, joints etc.
- Automated generation of (bi-directional) production drawings (you can change elements in the production drawing and the model will automatically be updated or you can change the model and the production drawing will be updated automatically).
- Many catalogues are available for all kinds of fixtures from manufactures or defined by the user.
- Recognitions of equal parts. Change one part and all others will be adapted automatically.
- Automated labeling of the elements containing position number, weight, length/width etc.
- Parametric elements like beams, columns and stairs are available including reinforcement.
- Algorithms are available for mesh welding robots like Progress, AWM and Filzmoser. During the generation of the reinforcement the constraints of the robot are taken into account to be sure the created mesh can be produced.
- Fully integrated with Scia Engineer for automatic reinforcing slabs based on Finite Element calculation.
Allplan precast is available for the following elements:
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Walls
- Solid walls
- Double walls
- Brick walls
- Sandwich walls
- Wall panels
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Floors
- Solid floors
- Lattice girder slabs
- Prestressed) hollow core slabs
- Brick floors
- Bubbledeck floors
- Cobiax floors
- TT slabs
- Roof slabs
- Beams and Blocks
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Structural Elements
- Stairs
- Beams
- Girders
- Columns
- Foundations
- NO limitation!
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3. Production: PP Manager |
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An ERP system is often considered the backbone of an enterprise. Although there is an element of truth in this statement, ERP systems do have a few shortcomings. One of the most striking is perhaps their lack of ability to deal with graphical information combined with non standard products.
The production department in precast companies is often confronted with a high variation in elements and shapes, which implies the need for graphical information that most standard ERP systems cannot deliver.
PP manager is designed around this graphical information, and lets the user decide to either work with the graphical model or with the Bill of Material.
► more about the PP Manager
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PP manager unites all company software and provides a central data control system. It takes up the BIM philosophy to its full extent right into the company. There are several exchange methods, such as IFC interface, ERP interface and direct links with Allplan precast and Scia Engineer.
Moreover, PP manager uses an SQL database, so all SQL reporting and exchange functionality is applicable to PP manager.
PP manager is module based. It minimizes the purchase costs and simplifies the user management. Each module is developed for a specific department of a precast plant. We offer following modules:
Technical Information Manager
In this tool, all project information is gathered and available for the user at his fingertips. As the name is indicating, all information can be viewed here. This goes from a graphical representation of the model over the indication of the statuses to detailed information on each element.
This module gives you the possibility to follow up your projects at a glance . A color scale is applied on the graphical model to identify the current status of each element and each part.
The user can also define production, delivery and assembly phases and assign elements to it. To a planned element is assigned a phase number as well as the corresponding data of the phase. |
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Each phase is then visualized according to its settings, and the planned sequence can be simulated graphically. In other words, planning errors on the building site will be eliminated in advance. In the future a connection to other planning applications, such as Microsoft Project Planning, will be foreseen.
Delivery Manager
After the assembler, the delivery manager is the next step in the process. The assembler hands over a rough planning to the delivery manager, where a more detailed delivery planning is made. The delivery manager is based on the principle of stacks, which can be placed on a transport (lorry, ship, airplane…).
The planning of these stacks is done graphically, automatic checks for stability and axis loads are available during the planning. Also extra delivery materials can be added to deliveries, and delivery notes can be generated. |
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Production Manager
The production planner is designed to plan the production of your concrete elements. The planner can handle long beds and tables (so-called production units). For the planning a list of not yet planned elements that should be delivered within a certain timeframe can be selected. Again the detailed production planning is worked out graphically, since planning optimization and planning control aren’t possible without providing these graphical details. A calendar is available to access the planning, and add extra information to certain production units on a given moment. This can be for example: the maintenance of machines, a holiday and much more. Another advantage of this system is the possibility to claim production capacity in the future. This calendar is the heart of the production manager, and all functionality is accessible through this calendar.
We provide graphical representations of:
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- The whole hall, with the production facilities inside, and a production situation for a given moment.
- The production units, with the graphical planning on it.
- The elements, with or without details (such as reinforcement, fixtures…).
- The whole model of a project.
Multiple Project Resource Planning
| An application we are working on is to plan your resources across different projects. Based on the normal cycle for a precast project (defined in predefined templates), the actual project and the defined delivery date, a resource planning can be generated. This is done for each individual project. Based on that, the program calculates the required resources in time for each individual resource. The loading per resource in time can be visualized graphically . If a specific resource is overloaded, the responsible manager can reallocate the resources in time to overcome the issues. The planning starts with a global planning based on m3 or m2 and during time it will be refined when more accurate data comes available. There are different roles defined and each role has its responsibility and access in order to adapt the planning, e.g. the delivery date can only be changed by the project manager. |
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Reporting
| There is a separate reporting tool available. It offers a wide range of standard reports. As PP manager is based on an SQL database there is of course the possibility to expand this with more customized lists. Each report will also be accessible through an internet portal, so it is retrievable from all over the world. |
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Integration with ERP systems
Everyone knows that ERP systems are an asset to any possible company. However, a production environment often proves to be a real agony for these systems. Since precast factories are working with complex, and ever changing forms, they have a definite need for graphical information. We took up this challenge and developed a graphical planning interface to meet the needs of our customers. We offer several exchange methods with ERP systems to ensure a thorough integration of the software. |
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