THE ELCON BUILDING SYSTEM

INFORMATION PACK
The Elcon System is a proven technology of
robust construction materials that provide
benefits over traditional construction materials

L-shaped load bearing walls do not have to

be propped-up during construction

The impressive strength and robustness of the

Elcon System means that it is used to create
buildings over thirty stories high in some of
the most hostile building conditions
Contents

Introduction 4
How it all works 8
The Big Benefits 14
Design 16
The Innovative Idea 22
Procurement 24
Technical / Construction details 27
Contact 40
 Introduction

An introduction to Elcon
Some 40 years ago, a team of concrete engineers sought to make radical
improvements to flat panel construction technology, work which led to the
development of the Elcon of today and the unique building system that
bears the Elcon name.

The innovation created by that team was to cast two flat panels together
as one ‘L’ shaped panel as a load bearing element of a building structure.
The advantage of a ‘L’ shaped panel is that in most situations it does not
require propping and supporting during erection, and horizontal panel-to-
panel connections are not required. Panels can also be cast in large sizes
(up to 25m2 for normal storey heights) which means that the number of
joints is vastly reduced compared to conventional flat panel systems.

The basic panel Typical aperture option

 Introduction 5

Façade detail

Since the discovery of this innovation, the benefits of the ‘L’ shaped panel
system have been appreciated the world over with the successful, trouble
free completion of thousands of dwellings, apartments, hotels, campuses
and military cantonments. The strength and ruggedness of the system
means that buildings can be economically constructed to over twelve
storeys high, even in the most hostile geophysical environments, as the
Elcon Building System can be designed to meet seismic design building
code requirements in all countries.
6 Elcon Systems

Elcon continues to assist project owners, contractors and franchisors of the

Elcon system by providing a full technical back-up package that includes
all aspects of design. This support embraces everything from conceptual
massing to final working drawings that are produced using state of the art
design software. However, design benefits means little if the Contractor
does not possess the ‘know how’ to construct in a systemised way using a
production line methodology approach.

Using the Elcon system, structures can be erected twice as fast as can be
achieved by conventional building methods, a phenomenon that has to be
optimised by the rapid execution of finishing and services to fit out the
structures.

Elcon has vast experience of the management of this process and can offer
fast track construction project management as part of its technical support
package.

Typical flat configuration

 Introduction 7

Elevation of Worker Housing Project, UAE

Facade detail showing condensor unit screening

 How it all works

The Elcon factory

The heart of any factory is the equipment that produces its core product,
and for Elcon this is the battery casting moulds. The battery casting moulds
comprise a number of pairs of specialised vertical steel ‘L’ shaped moulds.
Conventional flat panel production is normally performed using horizontal
trays or beds that take up considerable space and need to be weather
protected in a permanently enclosed factory structure. As Elcon panels are
cast vertically, a fraction of the space is required for production and an
enclosed structure is only required in countries that have a predominately
cold climate, which means that production equipment is ‘semi–mobile’ and
can even be set up on the project site.

Starting production
All that is needed to start production are the Elcon battery moulds, a
gantry or similar crane for handling finished product, steel reinforcement
and concrete. While it is preferable for a factory to have its own concrete
making facility (batching plant) an Elcon manufacturer does not always
have to own and operate one. Concrete supply can be outsourced and
ready mix suppliers can establish and operate a concrete making facility
within an Elcon factory. Once a concrete making facility is established, the
basis of a precast factory is in place along with opportunities to make
ancillary precast products such as floors, staircases and even paviors, kerbs
and drainage goods.

The Elcon Battery Moulds

A standard L shape panel

 How it all works 9

The battery mould

The vertical battery moulds comprise pairs of casting cells, typically 14

in a minimum two mould set up. Most Elcon factories usually comprise a
four mould battery that gives the capability to produce 28 ‘L’ shaped wall
panels in a single day. All cells have a system of curing pipework and with
the addition of a thermal heater, two casts a day can be achieved, doubling
output. Each casting cell is adjustable, which means that a ‘L’ shaped panel
can be cast to any size up to 6m long ( long leg ), 2.5m ( short leg ) and
up to 3m high.

As with any moulding process, it is essential that no deformation occurs

within the mould during casting. The moulds are therefore very robust
structures made from structural steel sections and plating. Once concrete
is poured into the moulds, encapture bolts and tie rods fasten the cells
securely to each other and the complete battery is then pressurised via a
series of hydraulic rams.

On reaching initial curing, the hydraulics and encapture systems are

released, the leaves forming the casting cells are opened and the formed ‘L’
shaped wall panels are extracted by gantry crane. Panels are then stacked
and left to cure before transportation to site.
10 Elcon Systems

L shapded panels being formed in the battery mould

 How it all works 11

The flexibility of the Elcon panels - a series of different apertures can be formed
12 Elcon Systems

‘L’ shaped panel uses

The final product, being of high strength concrete, is typically used as a
load bearing wall member for most types of building structure, and many
different flooring systems can be used with them. As the ‘L’ shaped panels
have great strength, most structures using them do not need columns or
beams. The system is ideal for building compartmental structures such
as housing, apartments, schools, hospitals, student accommodation and
hotels, in fact any building with rooms of up to a 10 metre span. Elcon’s
track record over the past 30 years provides proof of the variety and
flexibility of the system’s uses.

The system allows for stategic planning and construction

How it all works 13
 The Big Benefits

Speed
The ‘L’ shape means the panels are self–supporting and so in addition to
the benefit of effectively placing two panels at the same time, the panels
do not have to be propped during the installation process, which makes
the erection process far quicker than with any other precast panel system.
A three man gang with a crane can place around 30 ‘L’ shaped panels in
a day, while a typical three bedroom apartment may have around 10 ‘L’
shaped panels depending on room configuration, which means that three
apartment structures can be erected in just one day by a three man gang.

Economy
Several factors make the Elcon Building System more cost effective than
other building systems:

i) Low Capital Cost – The Elcon equipment and factory infrastructure

costs are much lower than for conventional precasting, which makes
for low fixed overheads, a benefit that can be passed on to Elcon
customers.

ii) L abour efficiency – Vertical battery casting uses labour more efficiently
than conventional precasting.

iii) Mobility – Elcon factories can be easily and quickly established near
project sites, which means transport costs can be reduced and JIT
deliveries are easier to make.

iv) Smooth finish - Elcon panels are smooth finished so no plaster or

render is required to obtain a smooth wall finish as with conventional
building techniques.

v) F rameless structures – Elcon wall panels do the job of building frames

such as columns and beams. Conventional walls in multi–storey
buildings are designed as infill panels within a framed structure
because of their low strength properties: they need a frame while
Elcon structures do not.

vi) F inancing – Fast construction times mean earlier completions, which

means less financial exposure and reduced construction funding.
 The Big Benefits 15

vii) Construction simplicity – The simple production process means that

the required work force is mainly unskilled and semi–skilled labour.

Strength
No corner joints and fewer connections in the ‘L’ shaped panels makes for
great strength, and being solid reinforced concrete also helps! The strength
of the Elcon system means it is one of the few precast systems in the world
that can be used in seismic environments in a multi–storey format.

Energy efficiency
Concrete has exceptional thermal mass properties, which means that it
is a great store of warmth in the winter and of coolness in the summer.
Externally insulating Elcon external walls with cladding systems means a
very energy efficient building can be built, as this effectively isolates the
structure from external ambient temperatures, so rooms stay cool in hot
climates and retain heat within the concrete structure in cold climates.
Concrete is also a very dense material that makes it extremely resistant to
the transmission of airborne sound, and so houses and apartments built
with the Elcon system provide a quiet environment for occupants.

Robustness
Concrete is a very durable material with negligible maintenance
requirements, and it is inherently fire resistant and watertight, a factor of
interest for insurance companies and building warranty providers.

Street scene elevation of UK affordable apartments

 Design

All building projects start with design. The Elcon system is particularly
flexible from a design perspective and the appearance of a finished Elcon
building will generally match that of a conventionally built structure.
However, because Elcon adopts a systemised, off–site manufactured
approach to project construction, it is preferable to consider making a
building form suitable for systematization at an early stage. Elcon can help
achieve this via its London-based consultancy partnership. This partnership
enables Elcon to offer timely architectural and structural design solutions
when they are needed.

Elevation Sketches

Above: These sketches show three elevation treatments that could be adopted for typical
apartment development. Different treatments can be adopted for different blocks that would give
each its own character.

Opposite: Computer generated image of typical courtyard

Design 17
18 Elcon Systems

Computer generated image of typical street view

Design 19
20 Elcon Systems

Elcon takes full responsibility for all aspects of structural design including
production of working / shop drawings and the structural design
calculations that are necessary for a project owner to obtain the necessary
local consents and approvals. The ‘L’ shaped system permits considerable
layout design configuration flexibility and lends itself to an infinite variety
of designs from simple cubicle type accommodation to large, multi–
occupancy villas and apartments, to hotels, hospitals, schools and other
large buildings. This design flexibility and the ability to make different
sized and shaped panels, gives designers considerable freedom to create
interesting buildings. Most other systems are modularised and therefore
have less design flexiblity that tends to result in dullness and uniformity for
mass building projects.

Building proposals often feature the need to construct many units in the
fastest possible time and the resulting elevations are disappointing, dull
and overly uniform. Using the Elcon system, designs can be regionalised so
that new buildings blend with the cultural, historical and aesthetic qualities
of an area. Elcon believes that design can be enhanced using the Elcon
system, while remaining within cost and time constraints. Retaining an
overall planning concept as it stands, minor adjustments to elevations can
be made to enhance the visual presence and aesthetic quality of a building
without sacrificing time or budget.

Block C Exploded Isometric

 Design 21

Opposite: Exploded drawing showing the construction of a typical flat

Below: Model showing internal arrangement of Elcon panels

 The Innovative Idea

Concrete technology has passed through unprecedented development in

the last 10 years and Elcon has matched this progress in several areas:

i) Elcon uses self–compacting concrete as a preference in most of its

factories as it gives a superior finish and obviates the need to use
vibrators during the casting process. It also produces higher strength
and requires less labour to place the concrete.

ii) The jointing of panels and tying-in of floors is an essential detail in

structural design and practical installation aspect of precast structures.
The Elcon method, however, does not rely on welding reinforcement
or mechanical connectors between the reinforcing bars used in
connections as the system works with reinforcing bars located in
tubes, between floor planks and in edge beams, that are all grouted
and bonded together to form a monolithic type structure.

iii) Elcon works with the UK’s Building Research Establishment to develop
R.F.I.D. technology, which in simple terms sees a microchip that stores
manufacturing and QA data placed in each panel. This not only serves
as a permanent record accessible by anyone with an appropriate
reader, but also enables the tracking of a panel from manufacture to
installation.

iv) Elcon developed a Management Information System for its

manufacturing process that starts at initial design. Design partner,
John Robertson Associates of London, in conjunction with Elcon, has
developed software that generates panel profiles as a building is
architecturally modelled. These panel profiles are issued in the form of
schedules that are fed into a MIS as production information, including
the preparation of individual component manufacturing drawings.
 The Innovative Idea 23

Through the MIS, Elcon is able to monitor production in any factory via the
internet. Elcon’s Technical Centre provides all production information and
factory managers receive training in recording production and installation
data in the MIS. The Technical Centre monitors this information and QA
data, and can alert a factory about any variance that might affect a finished
product or the manufacturing and erection programme.

As production methods used in industry are adopted by the construction

community, and with emphasis now on off–site manufacture, Elcon will
remain at the forefront of innovation. After all, that is where Elcon started.

An Elcon panel being handled in a stocking yard

 Procurement

Elcon offers the following options:

i) The sale of Elcon equipment with a license to use Elcon technology

together with technology transfer package.

ii) The formation of a Joint Venture to carry out suitable design and build
construction projects utilising the Elcon system under license.

Elcon’s mission is to implement its technology anywhere in the world

to improve construction methods, improve building standards, to make
construction safer and more efficient to the betterment of every member of
society. To bring this about, Elcon has an extremely flexible approach to the
procurement of its patented technology. As long as its clients and partners
have similar objectives and share these values, then agreements can be
formed, transactions completed and new Elcon businesses created.

Opposite above left: Fabric reinforcement being placed in the battery mould prior to casting
Opposite above right: Casting in progress
Opposite below left: Fabric reinforcement being handled by a gantry crane
Opposite below right: Concrete placing in the battery mould
Procurement 25
Technical / Construction details

The following details show how various

interfaces are designed and constructed.
These are typical situations where Elcon
panels are used in conjunction with precast
hollow floors in multi–storey apartment type
structures. Individual projects vary as do
local building codes and country standards,
therefore ‘typical’ details vary depending on
such local conditions.
28 Elcon Systems

L-Shape Wall Panels

The L shaped panel being joint free, has inherant rigidity which gives the
Structural Engineer distinct freedom in his design. All walls are capable
of being load-bearing and this again makes the design of floors less
problematical as in most systems (and traditional systems) internal walls
are not usually load-bearing, and therefore the Engineer is limited to the
external and party walls to give support to the floors. The panels can be
cast up to 6.6m long on one leg and 2.4m on the short leg, and up to
3m high. Having the ability to manufacure panels of this size means that
less, and sometimes, no joints are involved thereby reducing or removing
a source of maintenance or possible defect. The L shape means that the
panel is self supporting which makes the erection proceedure and handling
much easier and safer than that for most other systems, particularly flat
panels.

Floor Planks
The load bearing qualities of the wall panels means that the designers and
the end user have considerable freedom of choice in selecting the type of
floors they require. The Elcon Building System provides options for using
solid, hollow, pre-stressed, cored or troughed precast concrete floors. The
floors can be smooth finished enabling floor screeds to be dispensed with
in certain situations. Where Elcon are requested to provide floor screeds,
these are reinforced to prevent cracking and to permit plastic electrical
distribution conduit to be incorporated in the screed below the fabric
reinforcement.
 Technical / Construction details 29

The most popular floor system is a composite floor of precast concrete

slabs with a structural reinforced floor topping. The topping acts as a
floor screed and the precast slabs have a smooth soffit for direct paint
application.

Battery Moulds
The patented steel battery moulds in which the panels are cast are capable
of a very high rate of production and are equipped with hot oil pipework
and sensors which enables two casting per day. A normal factory set-up
will feature a four mould installation with each battery carrying seven cells
being sufficient to produce 56 panels in a 24 hour cycle. The sizes of the
cells are adjustable to accommodate different panel leg lengths. The soffits
to the moulds are also adjustable enabling different height panels to be
cast. The cells are formed with steel leaves which open horizontally by a
unique racking system to allow each cell to be set with fabric reinforcement
and plastic conduiting and to be closed up when the mould is set and
ready to receive concrete. Once one cell is set and ready for pouring, the
next one can be opened and the process repeated. Once the complete
battery is set, the main clamps are secured and the hydraulic ramps
activated. These devices ensure that there is no movement of the cells, end
formers or soffits during deposition of the concrete and are essential to
ensure the finished panel is cast within the very tight tolerances required.
The concrete used is dispensed from the batching plant and generally has
a minimum cement content of 350 kg per cubic metre. This is to enable
the concrete to have a high early strength sufficent to allow re moving
from the moulds after some 4 to 5 hours in conjunction with the hot oil
curing. After approval from the Q.A. Manager, the moulds are opened and
the concrete is tested to establish its strength whilst still in the cell and if
it meets the strength requirement, de-moulding can take place. The panels
are carefully removed from the moulds by the overhead gantry crane and
deposited in the curing yard where they will remain for some seven days in
order to attain approximately 90% of their final strength, sufficient for it to
be transported, fixed into position and loaded. After removal from the cells,
the steel plate lining the cell is cleaned and sprayed with de-moulding oil
ready for the next cast.
30 Elcon Systems

Floor Moulds
The floor moulds to form the floor planks can be in varied forms to suit the
particular type of floor required by the client. In most situations the moulds
will be steel pans laid horizontally with removable sides. Once the planks
have attaned sufficient strength, the sides are detached and the floor units
lifted out of the pans by crane. The quality of the concrete will again be
high in order to achieve the high early strength and hardness to prevent
damage during handling.

Staircase, Lintels & Feature Panels

The Elcon system is designed to enable all structural components to be
precast which entails the manufacture of the steel moulds necessary to
precast the components. Many other systems do not precast stairs and
therefore the time benefits gained by precasting walls, floors etc. are lost if
stairs have to be formed insitu. In addition, insitu casting invariably cannot
produce the same quality finish as concrete poured directly against epoxy
coated steel plate as in Elcon’s precasting process.
 Technical / Construction details 31

Design
Elcon have both in-house and Consultant engineering facilities which
enables designs to be produced speedily. As part of the total service
offered, Elcon takes full responsibility for all aspects of the structural
design and therefore produces full working drawings, calculations etc.
necessary to enable the client to obtain statutory and other approvals.
The L shaped system permits considerable flexibility in layout design
configurations and lends itself to an infinite variey of designs and layouts
from very simple cubicle type accommodation (student hostels, military
barracks etc.) to large multi-occupancy Villas and Apartments of a high
specification, together with Hotels, Hospitals and other large buildings. The
L shape, the size and load-bearing qualities of the system gives it inherant
rigidity and strength sufficent to comply with the Zone 111 requirements of
the California Code for Seismic Design. The system has been proven to 42
storeys high in order to be accepted as an approved system builder for the
Hong Kong Housing Authority. This design flexibility and the ability to make
different sized and shaped panels, gives Architects considerable freedom
to create interesting elevations. Most other systems do not have Elcon’s
design flexibility and therefore mass building tends to lead to uniformity
and dullness.
32 Elcon Systems

Finish
Elcon panels are cast in smooth steel moulds with specialised vibrating
equipment which gives a very smooth totally even finish. This means that
the panels need have no render or plaster finish and can recieve paint or
decorative treatment directly onto the panel.

Services
Plastic conduit for electrical service distribution can be incorporated within
the wall panel during casting together with holes to allow pipework to
pass through. This means that service designs have to be completed in
advance and this requirement indirectly provides a discipline to the project
consultants for the early consideration of services.

Joints
The size of the panels, the density and weight means that expansion
and movement is undetectable and there is only a minimal requirement
for designed jointing. The panels are bedded and grouted in a designed
waterproof grout in an external situation and a cement sand grout
internally.

Connection between panels and floor planks

Vertical integrity of the structure is achieved by utilising lifting hooks as
permanent reinforcement. Floor planks are located over the lifting hooks
from the panels below the wall panel above incorporates a pocket exposing
the feet of the lifting hooks within the panel. The lifting hooks from
each panel are then welded together, checked for quality and the pocket
grouted.
 Technical / Construction details 33

Erection
L shaped panels are self-supporting and this has considerable benefits in
the erection process. The panels are lifted off the transporter by crane and
placed in position on packers prior to grouting. During this process, the
panel requires an average of three men to manoeuvre the panel into place
and because no supporting stays or props are required, a panel can be
uplifted from the trailer and put in position in a matter of minutes. Erection
can always match production output and therefore the speed to construct
the building will be the same as the maximum output of the plant.

Speed
The advantage of precasting is invariably one of speed however, the Elcon
Building System is unique in precast systems by virtue of its exceptional
completion rate. It is quite usual for Elcon to complete over 100 structures
in a month and to complete the fitting out, a Contractor has to be able
to resource materials and labour to complete his work at the same rate.
If this is achieved, then the benefits of speed turn to economy. Quicker
completions lead to quicker sales and income, therefore the finance costs
involved are substantially reduced, additionally, if a contractor is able
to build 50% or 60% quicker, then he has the capability to increase his
turnover and profit by the same amount.
34 Elcon Systems

Economy
In most situations, the Elcon Building System is cost effective against
traditional and indiginous forms of construction for the following reasons:

• The Elcon system is more akin to a manufacturing / production

line system and therefore requires less skilled manpower per unit
constructed than traditional methods.

• The early enclosure of the building means that the construction works
are less affected by weather.

• The speed of the system brings about indirect economies as outlined

previously.

• The system obviates the need for wet trades, principally wall renders
and plasters reducing the cost of finishing trades.

• The incorporation of electrical conduiting reduces the cost of electrical

installation.

• The requirement for fitting out works to match the speed of erection
of the structures means that bulk purchasing is required thereby
creating an opportunity for discount purchase.

• Reduced waste due to the mechanisation process and the exact siting
of service locations, apertures etc.
Procurement options
Elcon’s approach to flexibility in design applies equally to procurement:

• Elcon will undertake the construction of the system directly by

participating as a Prime Subcontractor to a Main Contractor

• Elcon will form a Joint Venture with a suitable Main Contractor /

Developer / State or Government body.

• Elcon will enter into contract directly with the land owner / client
to supply and erect the system or the complete project as a turnkey
Contractor

• Elcon will sell its equipment to the client with a technology transfer
package to train the client’s workforce to operate the system under
licence.
36 Elcon Systems

0.150

100 x 50 x 2.5mm RHS

150mm ELCON Wall panel

C35 Concrete fill T16

T20 or Ø 9mm Steel

strand (pre-stress)
Peripheral tie

T16 Horizontal tie

T20 Vertical tie

EXTERIOR DETAIL –
SINGLE BEARING

0.150

100 x 50 x 2.5mm RHS

150mm ELCON Wall panel

C35 Concrete fill T16 H

T20 or Ø 9mm Steel

strand (pre-stress)
Peripheral tie

T16 Horizontal tie

T20 Vertical tie

EXTERIOR DETAIL –
NON-LOADBEARING
 Typical connection details 37

0.150

100 x 50 x 2.5mm RHS

150mm ELCON Wall panel

Horizontal tie C35 Concrete fill Sand / Cement levelling screed

Hollowcore Floor Plank

T16 Horizontal tie

T20 Vertical tie

INTERIOR DETAIL –
SHARED BEARING

0.150

100 x 50 x 2.5mm RHS

150mm ELCON Wall panel

orizontal tie C35 Concrete fill Sand / Cement levelling screed

Hollowcore Floor Plank

T16 Horizontal tie

T20 Vertical tie

INTERIOR DETAIL –
NON-LOADBEARING
38 Elcon Systems

546 2635

150
150

Ø20 lifting hook

Joint Detail 19
ex 50 x 25mm
2825

2825
2 x A6 (A142)

3408

1155 5333

(L-hand)

5333 Joint Detail 19

2635 ex 50 x 25mm
150

3408
1155
546

150
Typical wall details 39
 Contact

Elcon International has licensees and associated

Elcon companies operational in the United Kingdom,
Saudi Arabia, Bahrain, Dubai, Iran and Nigeria

Elcon International Administration Office:

ERI House
19 Hereward Rise
Halesowen
West Midlands
B62 8AN

Tel: +44 (0)121 550 5505

Fax: +44 (0)121 585 6178
E-mail: info@elconint.co.uk
www.elconint.co.uk
www.elconint.co.uk