WIELAND PREFAB® MEETS EXPANDED CLAY CONCRETE FROM TINGLEV
Reference: Multi-family housing complex “N48” (Berlin)
Pre-installation instead of chasing walls Electrical installation becomes part of prefabrication – and is completely shifted from the construction site to the factory.
A construction project with first-of-its-kind character
The «N48» apartment complex in Berlin is a project that reimagines electrical installation in multi-story residential construction. Two buildings with a total of 62 residential units are being built using prefabricated element construction, offering three types of apartment. This made the project perfect for standardized, scalable construction.
The unique feature was that the entire electrical installation was integrated into the precast concrete elements at the factory. This meant chasing out channels, conduit runs, and on-site wiring were not necessary.
You can find more information about the construction project on the N48 project website
Standardization as an economic lever
The housing market situation demands efficient solutions for affordable housing. Construction and land costs can only be influenced to a limited extent; therefore, the decisive factors are process optimization and increased prefabrication. By repeating identical apartment types, the Wieland PREFAB® solution allows for reproducible, economical implementation. This results in a scalable overall concept, from digital planning to assembly.
FROM THE FACTORY TO THE CONSTRUCTION SITE
How prefabricated electrical installation works
See how all project participants work together—from integration in the factory to installation on the construction site.
ONE PROJECT – SEVERAL STRONG PARTNERS
From planning and prefabrication to on-site installation – the N48 project shows how the collaboration of all parties creates a seamless process.
Modular construction / Manufacturing
System solution & prefabrication concept
Electrical planning
On-site installation
Factory integration and new level of prefabrication
The production of the wall modules at the Tinglev plant is based on a modular construction method using lightweight concrete. Each module is digitally planned, reinforced, and cast. Even in the standard process, embedded components, openings, and structural details are prepared to precision at the factory.
This process is being consistently expanded in the N48 project. Electrical installation is no longer considered an afterthought, but rather an integral part of the manufacturing process. Wieland‘s pre-assembled cable systems were precisely positioned in the formwork and then directly encased in concrete.
From shell construction to a
functional building element
Anja Knoll of Tinglev Bauelemente GmbH describes this as a logical next step.
“The component no longer leaves the factory as a classic shell, but as a functionally prepared element. The integration of Wieland PREFAB® significantly increases the degree of prefabrication and makes the entire construction process more efficient.”
This approach requires a high degree of planning accuracy and bespoke factory organization. The load-bearing structure, formwork design, and electrical infrastructure must be precisely coordinated. Quality assurance is therefore more focused on the factory, where controlled conditions prevail. The expanded clay concrete building elements used offer advantages in terms of structural integrity and building physics. The material is comparatively lightweight, provides thermal insulation, and is resource efficient. Combined with the modular construction method, this results in highly precise, ready-to-install wall modules.
By integrating PREFAB® at the factory, the component no longer leaves the factory as a classic shell, but as a functionally prepared element with integrated electrical infrastructure. The degree of prefabrication increases significantly, interfaces are reduced, and the overall construction process is stabilized.
However, implementation requires adapted factory processes, precise formwork planning, and a high level of detail even in the early planning phases. Wieland Electric provided comprehensive support for the project. This included three-dimensional planning of the cable harnesses, projectspecific kitting of system components, and installation training.
Electrical installation becomes
part of prefabrication
Peter Kauf, head of the strategic corporate project infrastructure, Wieland PREFAB®, explains:
“Wieland PREFAB® offers a complete solution for the electrical equipment of industrially prefabricated buidings. From the sub-distribution board to the socket, as much added value as possible is shifted to prefabrication in order to sustainably reduce overall costs.”
New roll of planning
The project and the new construction method also represented a strategic development for planning. The biggest challenge lay in synchronizing the planning and manufacturing processes. Architectural engineers, structural engineers, MEP engineers, prefabrication specialists, and system partners worked in parallel and in close coordination. The result is reproducible formwork plans, minimized potential errors, and a high degree of planning certainty. This creates a scalable solution for future multi-story residential construction projects.
Planning becomes a
central success factor
Philipp Talaska, authorized signatory of Passau Ingenieure GmbH:
“If consistently implemented, this results in time and cost savings for the client. Furthermore, investments and projects become significantly more scalable, a high degree of cost certainty is achieved at an early stage of planning, and the ‘product’ is visible and tangible early on (virtual tours, etc.) and of higher quality overall. For us, this primarily entails a shift in traditional planning phases and their content. The key here is a high level of detail in the early planning phases. The coordination effort for site supervision is reduced, much is precisely predefined, and improvisation on the construction site is minimized.“
PLUG AND PLAY
ON THE CONSTRUCTION SITE
The real test took place on the construction site. For the electrical contracting company Spannungshelden GmbH, the factory-integrated installation represents a significant reduction in workload. Chasing channels, cable laying, stripping, and wiring on-site are largely eliminated. The Wieland PREFAB®components were delivered pre-assembled for each project and room. Even individual rooms were packaged separately and prepared for installation.
One technician clearly describes the difference: “The installation is exactly as easy as promised. The preassembled components, combined with pluggable cables, save us a lot of work and planning effort. Compared to conventional cable installation, the difference is enormous.“
The pluggable installation also reduces the risk of errors. Incorrect wiring is virtually ruled out, interfaces are clearly defined, and processes are standardized.
Complete more construction sites in the same time
Benjamin Tutic, Managing Director of the electrical contracting company Spannungshelden GmbH (Oranienburg):
“The advantage of the building elements with pre-assembled wiring is obvious. We save time on planning, preparation, adjustments, and ancillary work that would otherwise come with conventional installation. We can work on more construction sites at the same time than with standard installations. Finally, the customer benefits too. The time we save ultimately saves the customer on their project costs. A win-win situation for everyone involved.”
INCREASED DEGREE OF PREFABRICATION CREATES PROCESS RELIABILITY
All project stakeholders reach a clear conclusion: Construction time is reduced, interfaces are minimized, and cost certainty increases. The solution is scalable, improvisation on the construction site is significantly reduced, and the quality of execution remains consistently high.
Anja Knoll summarizes it: “The higher the degree of prefabrication, the less coordination is required on the construction site. Customers benefit from predictable assembly, reduced potential for errors, and high quality. At the same time, the integration of the electrical installation strengthens differentiation in the market.”
The planners are convinced that a higher degree of prefabrication is indispensable due to time pressure, shortages of skilled workers and increasing quality requirements.
THE N48 PROJECT IS FAR
MORE THAN A PILOT PROJECT
It demonstrates how a reproducible concept for serial multi-story residential construction can be realized through integrated, pluggable electrical installations.
ONE PROJECT. REAL EXPERIENCES. DIRECT EXCHANGE.
The following project participants offer insights into the practical implementation of PREFAB®—and are available to discuss planning, prefabrication, and installation.
Anja Knoll
Managing Director
Tinglev Elementfabrik GmbH
Construction partner for pre-assembled wall elements
Philipp Talaska
Authorized Signatory
Passau Ingenieure GmbH
Electrical planning office for residential construction project N48
Your direct line to
Wieland PREFAB®
Christian Merkel, consulting + support for Wieland PREFAB® concepts:
“The pilot project is a success model, in which all parties involved are not only more than satisfied with the result, but also highly motivated to continue the collaboration and tackle the next project.”
Leverage the experience from this project – and speak directly with Christian Merkel about your own plans.
