Polish projects

Concrete Strength Measurement

In 2007, we also introduced a maturity parameter-based initial concrete strength measurement. Regardless of the ambient temperature, the system makes it possible to define precisely the time after which the concrete within a structure has become strong enough to allow the removal of the formwork. The measurement conducted during the initial application of concrete involves: installing temperature sensors within a concrete structure, preparing 10 samples of concrete which are heated to the structure's temperature with the help of shields, and successive testing of the strength of samples. No samples are taken during consecutive applications of concrete. Only the temperature sensors are installed in the structure. The strength within a concrete structure is defined on the basis of the collected temperature data and pre-tested strength of the concrete samples. Concrete strength tests can be carried out directly at the construction site by reading the data from the sensors with the help of a laptop and remotely via the Internet. The measurement method is designed for site managers and supervisors of reinforced concrete works. To date, the system has been applied at the Osiedle Leśne IV, Osiedle Sansara, and Eolian Park I construction sites. 

Sindeo

Since 2007, we have been implementing the Sindeo system designed to monitor construction progress. The implementation process includes the construction sites of Grupa Mostostal Warszawa. The system is based on the application of specialised network cameras. It allows the operator to take pictures, record videos and store operations as well as real-time site image viewing from any place with Internet access. The system is intended for specific department managers, site managers and supervisors. To date, Sindeo cameras have been used at four construction sites: Belvedere Centrum, Osiedle Leśne IV, Osiedle Sansara, Eolian Park, the Laboratory of the Military Academy of Technology (under a joint project) and at the production hall of Mostostal Kielce.

European projects

Pursuant to the EU Framework Programmes, we are in the process of completing the following projects: 

EINSTEIN: Effective Integration of Seasonal Thermal Energy Storage Systems in Existing Buildings

The main objective of the project is to develop, assess, and demonstrate a low-energy heating system based on seasonal heat energy storage combined with a heat pump system. The system will provide heat energy for central heating and hot water needs within the existing buildings to considerably reduce on-site power consumption. The integration of the energy storage system with heat pumps will form one of the key achievements under the project. Thermal energy storage systems are known mainly across northern Europe and heat pumps are being applied worldwide. However, the integration of the two components is yet to be refined. A suitable heat pump does not exist, nor can anyone assess objectively the efficiency of the planned system. Both of these issues will be solved under the project.

Under the EINSTEIN project, two demonstration facilities will be completed. One of the facilities, bearing appropriate parameters to ensure energy for several buildings, will be completed in Poland. Mostostal Warszawa is one of the key participants in charge of this implementation. 

Com-bridge - An Innovative FRP Composite Bridge

The Com-bridge project aims to build Poland's first road bridge with the use of FRP composites (i.e. fibre-reinforced polymers). The project will be completed over a period of 29 months (from November 1, 2013 to March 31, 2016) under agreement no. UOD-DEM-1-041/001 of January 17, 2014 for the performance and financing of a project under the "DEMONSTRATOR+ Supporting Scientific Research and Development Works in Demonstration Scale" Pilot Venture.

The consortium consists of four units:

The planned Com-bridge demo facility will be built along county road no. 1411R in Błażowa (Rzeszów County), at the location of an existing bridge requiring immediate repairs. The planned simple beam structure bridge will have a span of 21m and width of 10m. The bridge is to be completed in the third quarter of 2015. 

Composite Footbridge: Development and Implementation of Composite Footbridge Production Technologies

The project was completed under the grant contract no. 4613/C.ZR7-6/2010 for financing the target project no. 6 ZR7 2009 C/07341 entered into with the Ministry of Science and Higher Education.
The duration of the project falls between 2010 and 2013.

The essential problem concerning bridge structures, including footbridges, is their durability associated mainly with the corrosion of steel construction elements and concrete reinforcement components. In addition, in the case of new bridge facilities built within urban communication environments, specifically within city limits, the problems related to traffic difficulties and the resulting material losses due to construction work are of a high significance. A technology for producing lightweight, easy-to-transport and quick-to-assemble module composite footbridges will be developed under the project. Polymer composites have a great future in bridge engineering, both in the construction of new and the renovation of old facilities. For new structures, the composites can be used to make load-bearing components (e.g. beams, cross sections, side sections, or rigging). In the case of old facilities, the composites can be applied to strengthen individual structure components in the form of external reinforcement. The main goal set forth by the consortium (Mostostal Warszawa S.A. and Materials Engineering Group Sp. z o.o.) is to introduce new structure materials in the bridge engineering sector to help solve a number of road infrastructure associated problems.  

Innovative Technology for Low-Noise Road Surfaces

Noise is any type of sound undesirable under given conditions that is harmful, intrusive and causing disorders in the recipient.

Currently, noise reduction forms a priority for Europe with special attention being paid to the noise generated by motor vehicles and at the tire-surface interface. Therefore, works are underway to develop technologies that will allow permanent solutions to be implemented for noise control related efforts.

 

The “Innovative Technology for Low-Noise Road Surfaces" project aims to implement the production of mineral and asphalt mixes designed to make a new type of road surface featuring low-noise levels. The basic property of the low-noise surface is its porous structure obtained by increasing the amount of free space in relation to other mixes. The MMA open structure determines other properties that have a favorable impact on the comfort of the pavement user without reducing the capacity of the layers at the same time. A porous mix applied to a road surface reduces the noise generated at the tire-surface interface and allows water to be removed from the surface during rainfalls. It also helps reduce water splashing and aquaplaning.

The noise generated by a moving vehicle starts to dominate the noise of a running engine at speeds above 50 km/h. For this reason, the primary use for the surfaces will be on express roads passing through cities and located in the vicinity of houses.

Noise reduction of 6-7 dB can be achieved by applying porous surfaces while the construction of sound barriers reduces noise by 7-10 dB. The optimum noise reduction is achieved with the use of sound barriers 6-7 metres in height. In addition, the application of a porous pavement reduces infrastructure construction costs and has a positive effect on the landscape.  

A characteristic feature of porous surface technology is that it needs to be adapted to weather conditions at the implementation site. This includes water and frost based designing. In addition, it requires the development of surface cleaning methods (due to possible mix pore clogging) and conditioning in the winter. The research work will last two and a half years. Once the research phase of the project has been completed, prototype sections will be made to allow the laboratory test results to be verified in real-time. Positive test results will enable the completion of the last phase of the project – preparations for the implementation that will last 6 months. The project is being implemented by the consortium consisting of: Mostostal Warszawa – consortium leader, Faculty of Civil Engineering at the Warsaw University of Technology, and Pavement Technology Division at the Road and Bridge Research Institute – consortium members. The unit in charge of supervising the implementation of the project and providing the funds is the National Centre for Research and Development.

Project start date – May 1, 2010.

Project end date – April 30, 2015.

Environment Friendly Hot Mineral and Asphalt Mixes as a Modern Technological Solution for Improved Asphalt Pavement Construction Performance

Due to increasing traffic loads and the need to build more roads, it is crucial to permit the application of mineral and asphalt mix pavements where unfavorable weather conditions prevail (temperatures below 5°C). Low air temperature causes rapid cooling of the mineral and asphalt mix during transport and rolling. This in turn translates into inadequate density of the mixture. Improper density will cause the road surface to become unable to bear traffic loads within its planned time of use without premature damage.

The MMA project aims to develop solutions that can, to a large extent, limit the low air temperature problem. This will become possible thanks to "warm" mineral and asphalt mix technology. It consists in modifying the mix so that its temperature at the final rolling efficiency phase can reach 80°C. This is 20-30°C less as compared to standard hot mixes. What is important here is that despite such a low temperature the "warm" mix may be condensed to the same degree as the hot mix. Moreover, it will also make it possible to lower the mix production temperature down to 120°C, thus reducing emission of gases harmful to the environment.    

The project is divided into two phases. Its first part includes planned tests first for asphalt and then for mineral and asphalt mixes. Project modifications will involve the application of additives with various effects on reducing technology temperatures. Three types of additives can be distinguished: waxes that modify the visco-elastic properties of the mix, chemical additives acting as surfactants, and zeolites that due to their "microfoaming" phenomenon cause the production temperature to drop and the mix to spread. 
During laboratory research, the most effective additives will be selected and the optimum amount of the modifier with relation to the weight of the adhesive/mix will be defined.

Suitable tests will be run for various types of mineral and asphalt mix so that the selected additive becomes multipurpose to the highest possible degree without interfering with the strength parameters of the mix.  

The second part of the project includes the construction of a prototype, i.e. the production of a sample series of modified mineral and asphalt mix needed to make a test section. The work will also include a possible modification project for the mineral and asphalt mix production plant.

Mostostal Warszawa S.A. coordinates the project involving:
Road and Bridge Research Institute - Pavement Technology Division and Warsaw University of Technology – Construction Material Engineering at the Faculty of Civil Engineering.
Project start date: March 3, 2010.
Research end date (applied industrial research and development): March 31, 2012.
Project end date: December 31, 2012. 

Multi-Dwelling Urban Building 2030 (MBJ2030)

The Multi-Dwelling Urban Building 2030 project features a holistic approach to improving the technical and performance properties of buildings. It is intended to achieve a goal consisting of two parts:

- To offer new structure, material and installation solutions as per the principles of sustainable construction; this will set the standards for municipal multi-family buildings to be used widely in 2030 – the MBJ2030 standard;

- To build a demo facility for testing the proposed solutions and to communicate the principles of the standard.

The research related issues of the project focus on general optimisation of the building design process and improvement of the existing renewable energy consumption, water consumption reduction and power control system operation concepts in multi-family buildings.

This will provide an opportunity to improve the overall properties of multi-family residential buildings, which will translate into improved quality of life for residents and a significant reduction in the negative impact on the environment. An MBJ2030 building will feature a BBE (Building Environmental Efficiency) indicator of > 1.5 (currently at 1.0).

Buildings erected in accordance with the MBJ2030 standard will be differentiated from existing buildings by a number of innovative features, including:

  • Effective room overheating protection in the summer;
  • Effective building thermal insulation;
  • Heat source in the form of a renewable energy and municipal network-based system;
  • Water and sewage system providing an option to reduce drinking water consumption;
  • Hybrid ventilation system;
  • Indoor air meeting high hygienic requirements;
  • Favorable environmental and ecological characteristics of the building's life-cycle;
  • Limited penetration and propagation of undesirable sounds outside and inside the building; - Integrated building management system.

 
The project envisages the erection of a multi-family building in the new standard as a demo facility. The project is coordinated by Mostostal Warszawa S.A. Project participants: Building Research Institute and Silesian University of Technology.

Other data:

Project start date – March 3, 2010.

Research end date (applied industrial research and development) – August 31, 2013.
Project end date: December 31, 2013.

Construction Work Reinforcement Technology for Acts of Terrorism

The project aims to develop a construction work reinforcement technology for cases when various means of destruction, such as explosives in terrorist attacks, are used. The threat of terrorism has made it necessary to identify the potential range of destruction and to create suitable means of protection to minimise the consequences of an attack. Currently, no enterprises exist to offer this type of service. The project implemented by Mostostal Warszawa, completed in cooperation with the Military Academy of Technology, will provide the national market with an entirely new service improving the physical safety of buildings.

Main objectives:

  • To identify the possible range of damage to facilities under terrorist attack;
  • To develop a method for assessing building structure resistance against means of destruction;
  • To define reinforcement design and completion methods;
  • To improve building structure resistance by recommending a suitable system of    reinforcements.