The best Know-how and IT solutions in the Precast Concrete

market

www.csgengineering.eu

CSG is the European leader for Technical Services in the Precast Concrete market.

Since ‘80s, CSG provides the major Companies the most integrated and advanced

IT solutions and methods, assuring the best integration, time and cost saving

between Design, Calculation, Project Management and Work Management.

Solutions are applied for Industrial, Commercial, Housing Buildings, and

Infrastructures.

Technology Consultancy Software

INTEGRATED DESIGN AND CALCULATION FOR PRECAST CONCRETE STRUCTURES

LegoCad allows an assisted design of precast structures, simulating all production and installation processes, BOM

Once the building is assembled, LegoCad can automatically create drawings (Shop Drawings, Bar Bending Schedules, BOQ) and reports for production and installation

It is clear that, in order to be more competitive today, in

addition to technologically advanced equipment, an efficient

corporate organization is fundamental. This both for the best

use of resources, and to show departments productivity in

real time, in order to understand market changes, which

products are mostly required and convenient and which

departments can be subject to improvements.

The proposed solution is made of two fully integrated

software packages: BIM LegoCad for design and engineering

data, and ERP P2000 focused on cost and time. LegoCad

consists of the following modules:

LAYOUTS

• Fast Layout design for proposal, BOM available

automatically

• Optional 3D animation and rendering

• Improvement (quality and speed) in design

execution

• Preliminary drawings

• Decrease of design errors

• Drawings standardization

STRUCTURAL CALCULATION

• Loads

• Structural frame from the 3D model, automatic load

analysis

• Calculation according to Euro Codes / Local Codes

• Reporting, column verification.

DESIGN COMPLETION

• Connection

• Automated Piece Marking

• Automated creation of Shop Drawings, BOQ

• Automated creation of Bar Bending Schedules, BOQ

• Field Irons, BOQ

• Installation drawings

• Design to Production Automation to operate factory

machine using design data

➢ Layouts ➢ 3D Model ➢ Structural Calculation ➢ Connections ➢ Project Completion ➢ Panels Project ➢ Production Automation

➢ Estimation & Proposal ➢ CRM - Customer relationship management ➢ Production Management ➢ Operations Planning ➢Barcode Labels

P2000 ORGANIZES AND MANAGES QUALITY IN YOUR COMPANY

P2000 is a valuable support to good corporate organization. It can give the full control of costing and timing of the jobs; the tracking of every piece. Can also compare production costs with sales prices; precision of Estimated cost is continuously

improved, based on production cost

ESTIMATION AND PROPOSAL OPERATIONS PLANNING

• Precise Estimated Cost for Production Transport and Installation. All of this based on ‘cost rules’. Estimated delivery date.

• ‘Cost rules’ can take care of the complexity of the job.

• Fast Estimation delivery

• Easy overview of all actual Estimations of the Sales Network.

• Cost analysis automatically updated

• To control all the Business operations by defining the Production Priorities at Job/Pieces level.

• Tasks and Priorities are monitored for Design Dept; Production; Transport; Installation.

• Continuous control of the actual Job Delivery date, towards the Contractual one (both for Jobs and Estimations)

• P2000 can know automatically in which bed (or group of beds) the items will be manufactured; the daily capacity of each bed, the non working days.

PRODUCTION MANAGEMENT

COST CONTROL

• Job data, Design data, piece marking and BOQ automatically available from LegoCad for every piece.

• Production tracking, storage and delivery with barcode label. Query and reporting.

• Raw material unit cost applied automatically is the warehouse WAC at the time of production

• Production cost are calculated quickly and precisely.

• Automated comparison between Estimated, Design, Production and Balance Cost by piece, job, production line.

• Continuously improve the quality of the following Estimations (for materials, manpower, transport, installation) basing on actual Production Cost.

CSG Information Technology via Panini 11 29017 FIORENZUOLA D'ARDA (Pc) TEL: +39 0523.981374 - FAX: +39 0523.981480

info@csgit.it - www.csgengineering.eu

WELCOME TO THE PRECAST CONCRETE WORLD

LAYOUT & BOM The name LegoCad represents the way a building is assembled; this software is based on a data-base of parametric formworks and is customized for each client. It allows a three-dimensional architectural assembly of the building, while operating with a two-dimensional approach. After defining a structural mesh, columns, corbels, roof, slabs and wall panels are positioned; in the design assembly phase changes and modifications can be made at any time.

All drawings (“views” of the model) are completed with dimensions that are automatically positioned, these drawings contain all elements needed for design; the position of the details are optimized following standardization requirements from different Customers. Eventually when the design is changed all the drawings are updated automatically (drawings and quotas).

BILL OF MATERIAL All the elements of the model are automatically available, with their geometrical details, in separate reports for proposals, orders, production and purchase departments.

3D MODEL LegoCad allows to create a 3D model compatible with Autocad and 3D Studio and to define the construction materials; a procedure is available to quickly define the environment (sky, landscape, trees, etc. ..) that surrounds the building.

Cast stone

Other materials Frames

Concrete

While presenting the proposal, it is useful to attach a drawing with a realistic picture of the building enabling the customer to understand what he is going to build; for the precast manufacturer this is also a way to differentiate itself from competitors.

With LegoCad it is possible to manage different types of panels finishing (homogeneous, horizontal squares, vertical squares) and for each area assign a material that is reported in the 3D model.

This simple procedure allows to fast obtain a 3D model complete with camera view.

Parametric and color customized joints

Windows where transparent or reflective materials and customizable color frames are applicable

Customizable cast stone

STRUCTURAL CALCULATION LegoCad is able, starting from the architectural design, to develop the 3D frame of the structure and to calculate the self - weights of each element related to its geometric and mechanical characteristics. The program also allows to assign dead and live loads, directly applied to the structural elements.

The structural frame obtained can be interfaced with various calculation and verification programs.

During the calculation phase, linear and non linear static analysis (included second geometric order), dynamic modal response spectrum analysis are performed, according to existing rules (eg. Euro Codes) and as required by the customer.

It is possible to get both graphical and numerical information from results of calculation; the deflected shape of structure and actions diagrams for each element can be shown.

The results are grouped into a database for easy consultation, allowing a flexible and fast identification of critical strength-displacement situations. Output data list is defined by user.

Assuming a type of steel reinforcement and stirrups for the column, it is finally possible to calculate the resistant interaction curve for all significant sections and check them.

CONNECTIONS The fixing connections are very important for the concrete precast structures because, through them, the linkages among the different structural elements that constitute the building are executed. The connections are subject to vertical and horizontal actions, as for example their own weight, wind and seismic actions, and for this reason they must be designed and checked to transmit all the stress actions, to prevent sinkings or settlements not expected in the design phase. Once the architectural design phase is ended, LegoCad allows to analyze and to position the knots that fix the structural precast elements to each other. Knots loaded in LegoCad can be commercial connections or user defined connections. Only in specific situations (non standard knots ) the inserts will be positioned one by one. LegoCad includes an archive of standard knots (commonly used in the market and used by concrete manufacturer) for the following connections:

Footing – Column Panel – Beam

Column – Beam Panel – Slab

Beam – Beam Panel – Panel

Beam – Slab Slab - Dome

Panel – Column Panel - Panel

During knots insertion, once the user has defined the type of connection to be used, LegoCad goes on by placing the respective inserts (boxes, profiles, …) on the different elements considering the production companies rules, also checking distances from elements side, the capacity for suspension elements, any interference among different inserts. When restrictions are not respected LegoCad reports the error to the user. How to use Example of panel-column knot: Once the architectural design is ended, the user chooses, from the KNOT menu, the knot typology to insert, for example panel–column (PAN-COL). Automatically all typologies on market and stored in the archive are proposed. After choosing the knot, the user, driven step by step by the program, defines the elements where to apply the inserts. The program automatically positions the inserts, building the knot, on the panel and on the column. Any change in the knot position on the architectural design will determine the update of the inserts positions in the elements carpentry drawings. In specific situations, when it is not possible to use commercial knots, it is possible to use generic knots defined by the user. While closing the order, the program automatically generates the used knots and the kit cast and assembly inserts summaries.

DESIGN COMPLETION After the Layout and the Customer’s order confirmation, the design completion will start with the positioning of the connections between the various precast elements (panels - columns, panels - beams, panels - panels, beams - columns, etc. ..). Appropriate macros, that can calculate the elements weights and consider the typical dimensions of the connections, allows to position automatically the embeds on the related precast elements and to validate compliance with the connections’ rules can avoid use of wrong connections.

After having completed the model of the building, LegoCad is able to identify all the elements, recognize the different ones (by size, form, inserts…) and assign a piece marking to each one, updating the installation drawings, draw up the production sketches, Bar Bending Schedules and provide all calculations of materials BOQ used in the project.

With this system production sketches are always drawn up in a uniform way; to facilitate its use a document (called STP) is provided to describe the reading and use specifications of architectural and executive design produced by LegoCad.

PANEL DESIGN General Parameters:

- Geometrical features, characteristics of materials (including maximum strengths allowed for different verification step ), steel reinforcements logic and positioning of polystyrenes, abutment stones.

- Loads agents: in addition to own weight, wind (allocation of increased involved area), earthquake.

Analysis of stress in various steps:

- Shakeout - Lifting - Own weight - Wind - Earthquake

Calculation of minimum areas of reinforcement.

K heat: Calculation of thermal conductivity, carried out in accordance with the standards UNI EN ISO 6946 and subsequent changes. The amount of heat that passes through the panel is calculated considering the material type and sections.

Kn

Ko

Distribution of reinforcements in panel edge beams:

Design verification report:

PRODUCTION AUTOMATION The integration between the design and production processes makes possible to reset errors, to reduce communication time between technical and production departments, to avoid conflicting documents because of missing updates, and also to manage Customer’s change requests in real-time. The designer enables the production of the verified elements and not subject to changes, he can also set the installation sequence.

The technical designer defines the filling of moulds for the coming working days selecting elements from different job. For example picking one panel, this is placed on the mould, it is hatched and the date of production planning is added. It is possible to optimize production, switching from one job to another; the production plan can be easily updated using commands like move day of production, re-optimize mould etc.

The planning can provide the following reports for each day / cycle processing (sorted by mould positioning):

➢ Layout general drawing including the percentage of capacity usage.

➢ Drawings of each mould

Summary of concrete, cast stones and finishing with possible separation between 1st and 2nd cast.

Summary of embeds, connections, lifting and lightening sized elements.

Summary of steel reinforcements (Bar Bending Schedule) by type, bar size and moulding.

Production sketches of the precast elements, in this way the table is printed at the time of production and there is no risk to have not updated versions.

Barcode labels with code and characteristics of the precast elements.

➢ CAD-CAM files UNITECHNIK format needed for production automation, for the geometry of the elements, the positioning of inserts, the types of processing, etc.

➢ CAD-CAM files BVBS format for reinforcement cuts and bending.

➢ Estimates and Statistics

➢ CRM - Customer relationship management ➢ Order management ➢ Production Planning ➢ Production Tags

IT ORGANIZES AND MANAGES QUALITY IN YOUR COMPANY

P2000 is a valuable support to a good corporate organization. It can give the full control of costing and timing of the jobs; the tracking of every piece. Can also compare production costs with sales prices; precision of Estimated cost is continuously

improved, based on production cost.

The precast market is increasingly competitive, as new technologies are available (quarterdecks, materials, etc.). And therefore also the

holding of relatively small size is able to equip and market products of good quality at an attractive cost.

And now it is clear that, in order to be more competitive today, you need, in addition to technologically advanced equipment, even a

good corporate organization. This allows you to maximize the use of resources and highlight real-time productivity of departments in order to

understand how the market moves, what products or what kinds of orders it is better to invest in and what is advisable for departments to

possibly cut. P2000 is the software solution that CSG offers.

This program combines the convenience and ease of use in a Windows environment with the various features of

its instruments.

The Integration of P2000 involves all branches of a company to coordinate their work and to play.

AUTOMATION AND QUALITY OF A PRECAST COMPANY Companies that benefit from this software see as this system a valuable tool in a more competitive market. People working in these companies do not fear for verification or constructive checks on the daily activities, but they are encouraged to improve their professionalism. Consisting of several modules integrated with each other, P2000 is a comprehensive tool for a company that decides to automate its work in a quality manner.

Estimates Planning Production • Offers with more realistic cost analysis.

• Lower expertise needed to assess difficulties of works.

• Possibility to understand and evaluate instantly all quotes of the commercial network.

• Automatic updating of costs on the basis of market value.

• Adaptation of traditional prices.

• Management of moulds occupancy schedule.

• Ability to assess the timing of production and to make any change to optimize production and meet delivery times.

• Assessment of delivery times.

Project Management and Production Management Control and Budget Verification

• The design is automatically transferred to this module, reducing errors made inserting data, especially in case of variations.

• Better control in the different working stages.

• Availability of each element through bar code.

• Consultation view of the situation of each element.

• Verification of costs from start to order execution.

• Comparison of the quotation between committed order and production.

• Check Quantity of materials or their economic values.

CSG Information Technology VIA PANINI 11 29017 FIORENZUOLA D'ARDA (PC) - ITALY Tel: +39 0523.981374 - Fax: +39 0523.981480 info@csgit.it - www.csgengineering.eu

WELCOME IN THE WORLD OF PREFABRICATION

ESTIMATES AND STATISTICS Proposal is done by applying cost rules per every piece (for production, transport, installation) considering

materials and work cycles to properly estimate the cost of a building.

Moving from a traditional PRICE LIST to a cost analysis performed for each offers with RULES that assess the quantities of materials, manpower and optimizations at the stage of production and transportation.

RULES

Artefacts

Trasporti

Montaggi

Elements

Transportation

Assembly

Statistics Enable assessment of market demand and whether the types of manufactured goods are competitive for

more frequent use.

• Frequent Use of Products

• Summaries by geographical area or offer state

• Summaries by agent

CRM CUSTOMER RELATIONSHIP MANAGEMENT Today competitive search, passes towards sales force automation. The way the company defines its commercial strategy is crucial for results in terms of acquired orders.

The client has specific expectations on the behaviour of the trade negotiations and in stages immediately preceding and following the sale. New contacts are favourably impressed by sales representatives leaving a clear image of a well-organized and managed company.

Older customers stay more easily faithful to a company that, every day, considering its promotions, does not forget the needs of each customer, previous purchases, problems met and solved.

Standardizing sales deals is among the first targets; a clear business strategy that involves the identification of the main cornerstones with the identification of various sales paths, facilitates the reporting of situations and related statistics.

For commercial there are operational benefits using these software functions, such as the ability to manage various stages, to follow the progress and to record intermediate states and product documents.

In managing a sales network, sales force automation is essential, because it presents an image of an organized and homogeneous company and the customer favourably perceive that all commercial actions are consistent with a plan.

The sales management will keep under control all negotiations with relevant information and it will then be able to review and adapt its own sales policy also considering the margins of each potential order.

JOB MANAGEMENT It manages all processes affecting jobs, starting from technical department to production, storage,

transportation, installation, non precast items.

BOQ

LegoCad Design data BOQ is automatically available in P2000; then P2000 can add additional material (eg consumption material like spacers, demoulding oil ..) and manpower to properly have the cost of the pieces based on Design data.

Status Report

.

History tracking of the status of every piece.

Cost Control

Online comparison between Estimated, Design and Production Cost (both by Qties and Money) per piece, job, production line

OPERATIONS PLANNING The planning system for medium and long term performs an overview of all business operations, defining

priorities of execution of orders and capacity of technical department, production, transportation and

installation.

Planning can include:

• all designed orders: these orders can have to be produced only partially, in this case only elements still to be produced are considered.

• all orders acquired and not yet designed: to the elements of these orders all the information for their dimensional positioning in the mould are already associated.

• all possible estimates to be acquired: even for these elements, all information needed for production are already present.

MOULDS CHART

ORDERS CHART

Moulds Occupancy

Checking of production load by mould with the possibility to make changes to better optimize resources (internal and external) and meet delivery deadlines

Delivery planning

This module is completed by the SHORT-TERM PLANNING that, based on the planning proposal, defines exactly the elements to be produced in the coming days, considering the schedule of the moulds and trying to keep the delivery commitments.

PRODUCTION TAGS Aimed at quality control, at elements tracing rules, tags follow, with a serial number, the life of the elements

from the assembly of the reinforcement cage, to the work execution.

Print Print all relevant information related to manufactured elements availability and to the movements in Production, Storage and Transportation. Information will be visible to operators or available by reading the bar code printed on the card.

Production By reading the bar code the manufactured element will be automatically recorded in the daily production.

Warehouse It manages the storage of manufactured elements in the production areas, the barcode enables the identification of all elements by linking the manufactured element with the storage area.

Transportation Prints the accompanying document recording the transportation and updating the warehouse status.

LegoCad: 2D 3D Layout, and BOM

Customer

Step 1:-1 Selection of an experienced technician as a reference point for CSG.

-2 Data collection of information and docs needed by CSG to configure LegoCad (for Layouts only).

Information and docs: dwg drawings of al the type of precast products manufactured, along with their variabilities- .dwg of: columns, beams, slabs, panels, foundations etc.-Production schetkes of all the above items.- examples of layout and installation docs for your family of buildings.

Step 2:-1 training on the use of the program-2 check the correctness of the BIM products configured in LegoCad

CSGStep 1:-1 An experienced CSG technician is the reference for the Customer and first step is Data Collection.-2 Implementation of the BIM library with the kind of precast products manufactured/designed by the Customer

Step 2:-1 training to the Customer.-2 design of the first projects together with the Customer, tuning.

-Delivery: design of any kind of layout among them done by the Customer, BOM

LegoCad: Design Completion

Customer

Step 1:-1 Selection of an experienced technician as a reference point for CSG.

-2 Data collection of information and docs needed by CSG to configure LegoCad (for Shop drawings and installation drawings).

Information, dwg and docs: - Lifting, storage and transport rules for all pieces.- Connection Manual, or connection details including embeds, capacity, positioning rules. Installation drawings for several projects.

Step 2:-1 training on the use of the program-2 check the correctness both of the connections included into the BIM library, and of the shop drawings.

CSGStep 1:-1 An experienced CSG technician is the reference for the Customer and first step is Data Collection.-2 Implementation of the BIM library with lifting rules, and connections, manufactured / designed by the Customer

Step 2:-1 training to the Customer.-2 design of the first projects together with the Customer, tuning.

-Delivery: automated creation of Shop Drawings, Installation Drawings, Field Irons, BOQ

LegoCad: Bar Bending Schedules

www.csgengineering.eu - info@csgengineering.euvia Panini, 11 - Fiorenzuola d’Arda PC, Italy

Tel. +39 0523 981374

Customer

Step 1:-1 Data collection of information and docs needed by CSG to configure LegoCad (for Bar BendingSchedules).

Information and docs: - Rebar Reinforcing typologies and schema for all pieces- Existing Bar bending Schedules as example.

Step 2:-1 training on the use of the program-2 check the correctness of the Bar bending Schedules.

CSGStep 1:.-1 Implementation of the BIM library with all the information for Bar Bending Schedules

Step 2:-1 training to the Customer.-2 design of the first projects together with the Customer, tuning.

-Delivery: Bar Bending Schedules, BOM