Advanced Architectural Construction - Precast Concrete System by amal

Advanced Architectural Construction (ARC60104) Project 1: INDUSTRIALISED BUILDING SYSTEM Precast Concrete System

Adlin Sorﬁna Binti Ramli 0336092 Caryn Wee Shin Yee 0335535 Fathimath Zaha Zuhoor 0336185 Nur Amal Binti Azmi 0336210 Syamimi Binti Mohd Saifuddin 0335690

Table of Content Content List

1.0 Industrialised Building System

2.0 Precast Concrete System

02 - 04

3.0 Precedent Study

05 - 07

4.0 Proposed Apartment Design

08 - 22

5.0 IBS Components Features

23 - 25

6.0 Schedule of Modular Components

26 - 36

7.0 Fabrication Process

37 - 40

8.0 Construction Sequence

41 - 46

9.0 IBS Score

10.0 Conclusion

TES Evaluation

Peer Assessment

Reference List

Industrialised Building System 1.1.0 Introduction Industrialised Building System were introduced to Malaysia in the 60s by Ministry of Housing and Local Government. It is introduce to speed up building construction as well making sure the quality and affordability of the houses.

IBS were used to be an alternative to the conventional system that we are used to. It is a construction method technique which the components are manufactured in a controlled environment whether off or on site. The components are transported, assembled and position into a structure with less additional work given. The materials of the components are produced in a factory where quality control is not compromised on.

Types

Advantages and Disadvantages Advantages : ● ● ●

Steel Frame System Includes steel trusses, beams and a column portal frame

Timber Frame System Involves prefabricated timber truss beams and columns

Formwork System

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Generally involves concrete that moulded into different component

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Reduce construction time : Less construction time due to fabrication of the element can take place concurrently Save Cost : Reducing on-site workers,minimizing cost of transferring waste material, provides earlier occupation Optimised use of materials : precision and accuracy of the production can be achieve to produce ibs while reducing material wastage Durability : High-density precast concrete more durable to acid attack, corrosion, impact, reduces surface voids and resists the accumulation of dust High quality and better ﬁnishes : Quality control, high aesthetic end product Flexibility : More ﬂexibility in the design of precast element

Disadvantages : ●

Block Work System

Precast Concrete System

A system that uses interlocking concrete masonry units and lightweight concrete blocks

Includes precast concrete columns, beams, slabs, and walls and other component

● ● ● ●

High Initial capital cost : Initial capital cost of IBS is usually higher than conventional method Problem of joints : Sensitive to error and sloppy works Sophisticated plants and skilled operators : Relies on sophisticated plant Site accessibility : IBS requires sufﬁcient site accessibility to transport IBS components form factory to the site Large working area : Requires large working area for tower crane, factory, storage and trailer for the components

Precast Concrete System 2.1.0 Introduction Precast Concrete System has been introduced by the government in Malaysia since the 60’ as one of the IBS (Industrialised Building System) method in construction. It is also to enhance the importance of the prefabrication technology rather than conventional method.

Precast concrete system is a form of concrete that was made and formed in reuseable moulds, usually in controlled factory environment before getting transported to the construction site for assembly and installation. Usually used for structural component such as, walls panels, beams, columns, ﬂoors, staircases, pipes, tunnels, and more. Precast Concrete System are also economical and more practical to the construction process.

Types

Advantages and Disadvantages

There are three major types of precast concrete system

Advantages : ●

Large Panel System Consists of large walls and ﬂoor concrete panels connected in the vertical and horizontal directions

● ● ●

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Frame System Precast frames can be constructed using either linear elements or spatial beam-column sub assemblages

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Saves contribution times : Save time on construction and the risk of project is also less Quality assurance : Can regulate the quality and monitor the construction Cost-Effective : Reduces time, increase quality, productivity and safety thus the cost will be reduce Durability : High-density precast concrete more durable to acid attack, corrosion, impact, reduces surface voids and resists the accumulation of dust Aesthetic : Wide range of shapes and sizes are available to choose from with smooth ﬁnishings and thus the aesthetical value increase Safe construction program : No raw materials on site thus the casualties can be reduced.

Disadvantages : ●

Slab-Column System with Shear Wall

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Gravity loads supported by slab-column structure whereas shear walls withstand lateral loads.

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High Initial Investment : Heavy and sophisticated machines are necessary which requires a high initial investment. Transportation Issue : Construction site can be at a distance therefore transportation can be an issue Handling Difficulties : precast members are heavy and large which makes it difficult to handle without damage. Modification : Limitation In case of precast structures, it is difficult to modify the structure. 02

Precast Concrete System 2.1.1 Introduction For precast concrete design structure, temperature variations, concrete deep and shrinkage should be taken inro account as it may vary in the connection of the design leading to substantial damage. In order to have stabilizing units, the design of the connections should be made with the inﬂuence of different factors and with consistency to avoid any damage.

Types of Connection Welded Joints

Bolted Joints

Welding joints are made by welding plates or rods which are integrated with details in precast panels.

Bolted joints are made through ﬁxing embedded details in the precast panel and by bolting the plates. Mainly used for areas in which it is difﬁcult to weld. This method requires immense accuracy.

Welded joint with rod which is welded together with the loops reinforcement bar

Welded joint with plate. The steel plate is welded together with other steel plates that are used as embedded details.

Shows the welded joint with anchor plate.

Shows bolted connection of the wall with plate

Bolted connection of the walls

Precast Concrete System 2.1.1 Introduction Types of Connection Vertical joints of the wall panels : Wire loop connection

Horizontal joints of the wall panels

These are joints made from rope steel loops in a specialized box which are placed into the formwork before the panel is cast.

This type of connection consists of wall shoes and anchor bolts. This includes the steel box with anchor bars welded to the bic which are placed into the formwork together with the main and supplementary reinforcement

Anchor bolt Continuity reinforcement Wall shoe

Wire loop connection of two outer walls

Anchor bolt

The right location ﬁtting for bolt shoes

The wall is installed on pre leveled shim plates

Wire loop connection of outer and inner walls

The nut and washers are screwed on and tightened

Connection is ready for grouting

Finalized connection after the grounding hardens

Process of erecting walls with wall shoe

Precedent Study 3.2.1 Introduction

SERI JATI APARTMENTS , SETIA ALAM Developer : SP Setia IBS System used : Precast System Size per unit : 88m2

● ● c ●

Consists of 948 units and 10 storeys Achieved score of 83% for the vertical and horizontal Repetition criteria , maintained the quality Low forming and construction cost due to the use of precast and in-situ building components

Seri Jati Apartment Unit Typical Layout

Precedent Study 3.2.2 Construction System CONSTRUCTION SYSTEM USED IN SERI JATI APARTMENTS , SETIA ALAM :

Seri Jati Apartment uses conventional construction for its foundation and ground ﬂoor construction , including transfer beam to transfer the heavy gravity load of structural elements from above along with reinforced concrete components. Other than that , Seri Jati Apartment applies precast construction method with standardized components to facilitate its construction process while having g constant quality control.

Construction Process:

(A)

Construct structure’s foundation

(B) Installation of precast columns

(B) Installation of in-situ ﬂoor for Ground Floor and First Floor

(C ) Installation of precast components

(D) Process were repeated until the 10th Floor

(E) Installation of prefabricated steel roof truss with panels

Precedent Study 3.2.3 Building Components and Standardization of Sizes IBS COMPONENTS USED IN SERI JATI APARTMENTS , SETIA ALAM : Standardized Dimensions :

Majority building elements of Seri Jati Apartment uses IBS System of Precast Concrete method to construct. Building Elements including the Roof , Floor Slabs , Walls , Columns and Beams.

Precast Components

C B

Dimensions (mm/m2)

Precast Concrete Column

150 W x 150 L

Precast Concrete NonBearing Wall

150 W x 300 H

Precast Concrete Load-Bearing Wall

300 W x 300 H

Precast Concrete Beam

150 x 300

Precast Concrete Slab

200 x 4200

Prefabricated Steel Roof Truss

1610 m2

Precast Staircase

3000 H x 167 Riser x 250 Thread

Precast Bathroom

4.2 m2

Axonometric of Seri Jati Apartment , Setia Alam

Proposed Apartment Design 4.0 Introduction

The proposed apartment design implement the precast concrete system with the use of various precast concrete components such as columns beams, slabs and many more. This apartment has a total of 6 units and 3 ﬂoors with a 'X' shaped staircase at its center to access the units.. The size per unit of this apartment is approximately 100sqm, equipped with living room, kitchen, 3 bedrooms and 2 bathrooms.

Proposed Apartment Design 4.1 Orthographics Drawing Ground Floor Plan - SCALE 1:100

W2 D2

D1 D1

W1 D2

W1 D3

Proposed Apartment Design 4.1 Orthographics Drawing First Floor Plan - SCALE 1:100

W2 D2

D2 D1

D2 D3

Proposed Apartment Design 4.1 Orthographics Drawing Second Floor Plan - SCALE 1:100

W2 D2

D2 W1

W1 D2

D2 D3

Proposed Apartment Design 4.1 Orthographics Drawing Roof Floor Plan - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing North Elevation - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing South Elevation - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing East Elevation - SCALE 1:100

West Elevation - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing Section 1 - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing Section 2 - - SCALE 1:100

Proposed Apartment Design 4.1 Orthographics Drawing Section 3 - SCALE 1:100

SCALE 1:100

Proposed Apartment Design 4.2 Structural Drawings Foundation Layout Plan - SCALE 1:100

SCALE 1:100

Proposed Apartment Design 4.2 Structural Drawings First Floor Beam Layout Plan - SCALE 1:100

SCALE 1:100

Proposed Apartment Design 4.2 Structural Drawings Second Floor Beam Layout Plan - SCALE 1:100

SCALE 1:100

Proposed Apartment Design 4.3 Isometric View

IBS Components 5.0 Proposed Apartment’s IBS Features Repetition of Floor-to-Floor Height

Vertical and Horizontal Repetition on Structural Layout

4000 4000 4000

North Elevation

Ground Floor Plan

Maintaining the same height of floor from the ground floor to the top floor of 4000mm.

Structural components are constructed according to a repeated planned layout with vertical and horizontal grid.

Suitability ● ● ●

Modular coordinated Walls panels can be pre-fabricated and reduce on site labor Ease of construction

Suitability ● Allow prefabrication of wall components ● Ease of construction

IBS Components 5.0 Proposed Apartment’s IBS Features Precast Concrete Columns

Precast Concrete Beams

Suitability ● Reduce construction cost by having intentional manufacturing ● Flexible in variety of sizing and conﬁguration

Suitability ● Highly potential in producing consistent connections and construction outcome ● Sturdy and dense character limits Connection Detail

Connection Detail Mechanical splice

Precast Concrete Walls

Shim & grout Grout full

Cast-in-place concrete

Butt-weld

Suitability ● Reinforced with steel will make the long span concrete wall more sturdy ● Have load bearing capabilities and act as a stabiliser Connection Detail

Grout to cover recessed connection

Embedded plate

Roughened surface

Loose feld plate

Bolts

Grout to cover recessed connection

Precast beam

Shim & grout Precast column

Loose feld plate

Precast unit

Embedded plate

IBS Components 5.0 Proposed Apartment’s IBS Features Precast Concrete Staircase

Standardized Components

W2 D2

W1 D2

Suitability ● Accurate and ﬂexible during prefabrication process in factory ● More efﬁcient erection process

Uses Modular Coordination

Connection Detail Embed Steel Plate Concrete Staircase

Slab Landing

Bolt

D2 D3

Columns Sizes : Multiples of 0.5M

Beams Sizes : Multiples of 0.5M

Windows Width : Multiples of 1M

Doors ( Door leaf opening width) : Multiples of 0.5M

Suitability ● Prefabrication ensure quality control of components ● More efﬁcient and organised construction process ● Contribute to the Industrialised Building System ‘s scoring

Modular Components 6.0 Schedule of Modular Components SLAB COMPONENT SCHEDULE

Component Name

Slab SL1

SL2

Roof Slab

Staircase Landing Slab

Thickness (mm)

150

Width (mm)

10,000 mm

12000

1000

Length (mm)

10,000 mm

30000

1200

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components COLUMN COMPONENT SCHEDULE

Component Name

Column C1

Thickness (mm)

200

300

Width (mm)

300

200

Length (mm)

4000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components BEAM COMPONENT SCHEDULE

Component Name

Beam Beam 1

Beam 2

Beam 3

Thickness (mm)

350

Width (mm)

200

1200

Length (mm)

10000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WALL PANEL COMPONENT SCHEDULE

Component Name

Wall Panels Wall 1

Wall 2

Wall 3

Wall 4

Wall 5

Thickness (mm)

150

Width (mm)

9500

3200

4157

1993

9850

Height (mm)

4000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WALL PANEL COMPONENT SCHEDULE

Component Name

Wall Panels Wall 6

Wall 7

Wall 8

Wall 9

Wall 10

Thickness (mm)

150

Width (mm)

1993

4157

3200

9850

6775

Height (mm)

4000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WALL PANEL COMPONENT SCHEDULE

Component Name

Wall Panels Wall 11

Wall 12

Wall 13

Wall 14

Wall 15

Thickness (mm)

150

Width (mm)

9550

3200

4157

1993

9850

Height (mm)

4000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WALL PANEL COMPONENT SCHEDULE

Component Name

Wall Panels Wall 16

Wall 17

Wall 18

Wall 19

Wall 20

Thickness (mm)

150

100

Width (mm)

1993

4157

3200

2925

2825

Height (mm)

4000

Quantity

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WALL PANEL COMPONENT SCHEDULE

Component

Wall Panels Balcony Wall 1

Balcony Wall 2

Balcony Wall 3

Balcony Wall4

Balcony Wall 5

Thickness (mm)

150

100

150

Width (mm)

975

160

3860

1700

975

Height (mm)

1200

Quantity

Name

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components DOOR COMPONENT SCHEDULE

Component Name

Doors Door 1 (D1)

Door 2 (D2)

Door 3 (D3)

Width (mm)

900

800

700

Height (mm)

2100

Speciﬁcation

Timber Frame/Timber Door

Quantity

6 ( 1 per unit)

18 ( 3 per unit)

12 (2 per unit)

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components WINDOW COMPONENT SCHEDULE Component

Windows Window 1 (W1)

Window 2 (W2)

Window 3 (W3)

Width (mm)

1400

600

900

Height (mm)

1800

600

1800

Height from ﬂoor to window (mm)

900

2000

900

Speciﬁcation

Aluminium Frame/ Glass

Aluminium Frame / Glass

Quantity

48 (1 per unit)

12 (2 per unit)

6 (1 per unit)

Isometric

Plan

Modular Components 6.0 Schedule of Modular Components STAIRCASE COMPONENT SCHEDULE Component

Straight Staircase with Interlocking Landing

Name

ST 1 & ST 2

Isometric

Plan

Tread (mm)

1400

Riser (mm)

190

Floor to Floor Height

4000

Quantity

Speciﬁcation

Concrete steps (24) / Steel railing

Fabrication Process 7.0 Fabrication of Modular Components NORMAL CASTING FABRICATION PROCESS 1.

ASSEMBLY OF MOULD

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Workers must ensure the level and ﬂatness of the base before assembling mould for panel casting.

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Next, verify the mold size and dimensions are correct according to the design. Lastly, the workers have to check the squareness of the mould forms. ○ The workers have to check the squareness of the mould forms.

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2. MOULD CLEANING AND PREPARATION ●

After the assembly of the mould, it must be clean and free from debris and old mortars using remover or scaling bars.

●

Form oil or mould release agent is evenly applied over the mould surfaces.

●

The workers will have to check everything is properly secured such as the joints and edges of the mould, bolts, stoppers, tie rods, side props and rubber seal are undamaged.

Fabrication Process 7.0 Fabrication of Modular Components 3. FIXING OF REBARS/ CAST IN ITEMS/ PRESTRESSING STRANDS ●

The workers must check if the measurements of the rebar size, spacing and lap length are in line with the drawings.

●

The rebars, cast-in-items, corrugated sleeve pipes, recesses, lifting hooks and inserts must be accurately positioned and properly connect. With the use of fabrication rig, it can help to make sure the accuracy of rebars ﬁxing and spacing.

●

Only when needed, tack welding may be carried out to secure these items. To achieve the required concrete cover while casting, the workers should properly place and secure the the sufﬁcient number of spacers with the correct sizes.

4. FINAL INSPECTION BEFORE CASTING ●

The workers must check and verify that all details should exactly comply with the drawings.

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To check the mould ﬁtting conditions including blockout details.

●

To check the base mould level again especially for site precasting since other concurrent site activities may have shifted the mould level.

Fabrication Process 7.0 Fabrication of Modular Components 5. CONCRETING

6. CURING

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The workers must check that the concrete grade used is according to the design speciﬁcations and assess the workability of the concrete mix before placing the concrete mould, they must conduct a slump test.

●

After the concrete is poured, the curing process begins. During the curing process, the workers is to observe adequate curing time and desired environment.

●

The drop height of concrete mix should not exceed more than 1m. In more congestion areas, proper vibration and compaction should be carried out.

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With a controlled environment, it enables the product to properly cure and reach the desired design strength much quicker.

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Then, spreading and levelling of concrete surface level after initial set.

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Maintain the required thickness by use of screeder. It is recommended to use power trowel or ﬂoat to smooth the surface of the ﬁnishes.

Fabrication Process 7.0 Fabrication of Modular Components 7. DEMOULDING ●

Before demoulding process, cube tests should be conducted to conﬁrm the concrete strengths of elements.

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From the test, it will ensure the concrete strengths obtained for reinforced precast elements are minimum 10N/mm2.

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Next, it is required to loosen and remove all bots and pins and side mould forms before lifting.

8. FINAL INSPECTION/ TRANSFER TO STORAGE YARD ●

The workers must check the condition of the ﬁnished product and verify again the critical dimensions.

●

Identify all the markings to be placed on the elements showing the location, member type, size, weight and orientation as per shop drawing.

●

Lastly, check the elements have achieved 75% of their design concrete strength before delivery to site for erection.