In the Real Madrid “Sports City”, as part of an ambitious project developed by the prestigious Estudio Lamela, two residential buildings were built using industrialised construction systems:
Residence for the First Team
The building comprises a total constructed area of 8,500m² over 3 floors and has 60 rooms, in which both the first football and basketball teams of Real Madrid are housed.
The building was constructed using a mixed system comprising both traditional construction – performed by a partnership between FCC & San José, and building in situ the ground floor housing the common areas, lounges, swimming pool, and rest areas – and the floors of suite-style rooms, which consisted of industrialized 3D components manufactured, transported and assembled on site by Modultec. These rooms are oriented to the training fields and consist of modules 18 m long and 4 m wide, each complete with its own terrace and the proportional part of the corridor.
The use of this mixed construction model reduced the execution period to 8 months, with the assembly of the modules and finishing taking just 2 months.
Residence for Junior Players
The residence has two floors and a semi-basement level. The entire modular structure consisting of 44 modules was manufactured and assembled by Modultec within a period of 2 months, which reduced the total execution time of the building by 40%.
In this project, occupation within the Sports City itself was not such a critical factor, as it is accessed from the outside. The reduction of construction time was thus given priority only for the structural part of the building.
Some modules with a structural function were manufactured but later finished internally on site by the FCC & San José partnership, the construction company with overall responsibility for the works.
This educational complex measures 14,000m2 and is situated within a developed area of 40,000m2 including sports facilities.
It is made up of several buildings that cater for the full English educational system: from nursery education with independent facilities and access, up to the rest of the education levels, and including all respective teaching and sports facilities necessary for completing the educational cycle. There is also a large administration building, a 350-seat auditorium and a full sports centre.
In this project, all the educational buildings as well as the dining hall were built using 3D component construction systems, while the auditorium, sports centre and administration building – with differing heights – and the administration building’s curtain wall were constructed using 2D components. These were manufactured in their entirety in Spain by Modultec, and later transported by ship to Libreville, the capital of Gabon.
Given the particular economic and sociological circumstances of the local market at the time, the foundations also consist of pre-cast concrete footings that were manufactured in Spain and transported to their destination.
This project constitutes a clear example of how a large number of modules and the necessary foundations can be serialised and standardised. After being manufactured serially, construction consists of assembly of these elements on site.
Designed by the architects Gemma Vidal and Rodrigo Alaminos and located in the centre of Corró d’Avall in Les Franqueses del Vallès, this building has a total floor area of 2000m2 and was completed in a period of 4 months.
The need to complete the building on a tight schedule in order to have it ready for the next school year was a key factor for choosing an industrialised construction system using 3D components manufactured by Modultec in Gijón.
Thus, while progress was made in situ with the execution of the foundation and sanitary slab, the Modultec factory built the industrialised 3D components that make up the school. At the same time, the project design called for the execution of the works in two phases: the first to house the entire preschool programme and the administration and services area (L); and the second, with two floors, to be occupied by the primary school classrooms and the gym (I).
These industrialised modules are manufactured using a welded metal structure with floors of corrugated steel sheet and reinforced concrete. The enclosures were made with precast concrete panels on the ground floor and Corten steel sandwich panels with extruded polyurethane insulation on the first floor. The flat roofs are inverted with a Filtron slab finish, and all the interior partitions are laminated gypsum board, with a light auxiliary structure of folded sheet metal profiles insulated with rock wool. The modules were manufactured to a high degree of completion, including the centre’s facilities and all finishes, to optimise the lead time and minimise on-site work.
The company La Casa por El Tejado developed an interesting and innovative urban design in the centre of Barcelona where, given the scarcity of urban land available for the construction of new buildings, they carried out an exhaustive market study and found more than 100,000m2 of potential additional building space available on the roofs of buildings.
Employing a novel form of agreement with the building owners and neighbourhood communities, they bought up the roof rights and were thus able to not only develop in central areas of the city, but also assist in the rehabilitation of existing buildings.
This system of building extension is called «remontas» and consists of a lightweight industrialised system using 3D or 2D components in steel or wood. These minimise the loads on the building structure and the necessary reinforcements, thereby reducing inconvenience to the existing residents.
A “remonta” can consist of a single rooftop apartment, or even several floors of apartments for sale.
This mixed formula of new construction and the renovation of existing buildings improves the city centre, as it increases the housing supply on the market and provides enormous advantages in terms of energy efficiency, while also improving the liveability of existing buildings.