Where prefab concrete and electrical engineering meet: a ready-for-use package

Text: Annemarie Thönissen (Letterdesk) – Visuals: Isolectra

When an installation company, a prefab concrete manufacturer and a supplier of electrotechnical components decided to join forces, the result was a revolutionary new concept: innovative plug-and-play prefab concrete elements. This innovation was used for, among other projects, Hotel Bloemendaal aan Zee, according to Jordi Blanker, account manager at Isolectra BV, and Maurice van de Wijdeven, technical consultant and constructor at Prefab Beton Veghel BV.

Isolectra is a specialist in pluggable plug-and-play concepts. Blanker: “After previous experiences with pluggable installation during various tunnel-building projects, Techval wanted more and began to see the integration of concrete and electrical components as a promising innovation. This led to the question of whether we would be interested in joining forces with Techval to develop a system that could also be used in precast concrete floor panels. Although it was a major challenge, we were ultimately successful!”

Isolectra and Techval collaborated with Prefab Beton Veghel BV, a manufacturer and supplier of prefabricated modular concrete floors, on the Hotel Bloemendaal project. Blanker: “If you want to innovate, you have to be willing to take risks. Lucky for me, Maurice proved to be an exceptional partner during this project.” If you say “innovation” at Prefab Beton Veghel, Van de Wijdeven is sure to be involved. “You really need him, because an industrial process like this requires a novel approach. Based on our discussions, we came to the conclusion that our current system of pluggable installations in concrete can also be used for pluggable precast concrete floor panels, although we did have to make some modifications to the process.”

Innovative partnership in the construction sector
Van de Wijdeven: “Inspired by the question of whether we could incorporate these new facilities in our precast floor panels, we began innovating together. This was quite a new approach to collaboration within the chain. The direct communication with the company supplying the components made the whole process a lot faster and more efficient. The concept of incorporating plug-and-play pluggable components in precast concrete floor panels is truly revolutionary in the construction sector.”

Pluggable connections in the ceiling 
Blanker: “The location of Hotel Bloemendaal aan Zee is very popular among tourists. The prefab components significantly shorten lead times during construction and require fewer transport movements, which is ideal in a busy environment. It did require more careful coordination prior to the start of the project.” He continues: “That is why we worked together closely with the supplier of the prefab floors and the installation company during the preparation phase.”

This innovation called for the overhaul of internal processes. It is an industrial process and parties must be willing to deviate from existing operational processes and make modifications where necessary. Blanker: “Before we get started at the construction site, the entire electrotechnical installation is implemented in the precast concrete floor panels manufactured by Prefab Beton Veghel BV. In this manner, we ensure that all electrical facilities are incorporated directly during the concrete casting process.” A building is supplied with power and light using those junction boxes.

With Isolectra's unique pluggable concrete concept and the new pre-assembled ABB PMK80 concrete junction boxes with Wieland GST18^® and RST20^® connections, it is easier than ever to incorporate plug-and-play components in concrete elements in a fast and professional manner.

Higher quality with a new process
Blanker: “Prefab Beton Veghel BV is unique because it not only supplies concrete components, but also offers electrotechnical services. Together, we can offer real value when it comes to using pluggable solutions in concrete.” Van de Wijdeven says they conducted extensive tests during development: “Isolectra BV presents its pluggable junction box. It is then tested, refined, printed with a 3D printer and tested again. This ensures everything is in the right place beforehand.” As a result of the thorough development process, the quality standard is high.

Isolectra supplied the pluggable materials and the 230V installation, supervised the process and provided the 3D designs and models, sealing, labelling and information provision. Van de Wijdeven: “With the new junction boxes, the pluggable cables are also better protected. Because the system is plug-and-play, the risk of errors is lower. Isolectra BV has prepared everything very thoroughly, so all you have to do is use the right colour plug.”

Continuous innovation
Van de Wijdeven: “We continue to innovate and modernise. We believe the use of prefab elements is important, given what the future has in store. Doubly so in light of current conditions, such as the major staff shortages throughout the entire construction sector and the lack of adequately trained staff. We should embrace any solution that makes our work easier and faster without compromising quality.”

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