Prototype_2 Module by bnjmnph

PROTOTYPE_2 MODULE

2 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

THINGS TO KEEP IN MIND

1. SAFETY FIRST! Always wear the required safety gear on site helmet, gloves and appropriate footwear.

2. COLLABORATE Work with your group to maximize efficiency and minimize mistakes.

3. HELPING HAND When handling large materials, get a partner to avoid causing injuries to yourself and damaging precious materials!

4. CONFUSED? If unsure on instructions, consult the Specialist or Master Builder.

3 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

BUILDING DESIGN

SHERA ROOF SHEET

PURLIN COVER GUTTER

PURLIN

GUTTER SUPPORT

RAFTER GABLE FRAME

KITCHEN WALL STUDS

GABLE BOARDS

WINDOW SILL

CEILING JOISTS

WALL STUDS SHERA WALL CLADDING

CEILING BOARDS KITCHEN ROOF SHADE

SMALL PANELS

MONSOON WINDOW JOISTS SECONDARY FRAME

DOOR SUPPORT PANEL FLOOR TRACK FOYER LEGS

SHERA STRIP BIG PANELS FLOOR JOISTS SHERA FLOOR BOARDS CONCRETE FOOTING Will not be used in UM Workshop Prototype 3100

1000 1000 1000 950

450

68 1

2125

LOWER ROOF BEAM LEVEL

449 TOP OF FOOTING

770

GROUND FLOOR LEVEL

CUTTING SCHEDULE

COMPONENTS

ITEM Foyer Legs

FLOORING

WALLS

CEILING

ROOFING

PANELS

Floor Joists Shera Floor Planks Panel Floor Track A Panel Floor Track B

SHERA PRODUCT -

4" x 4"

6 Ft

2" x 4"

10 Ft

TIMBER PILE

25 x 200 x 3000

QTY

EXTRA

CUT SIZE

PIECES

100 x 100 x 670**

100 x 50 x 3040

[see Flooring Section]

1" x 2"

10 Ft

25 x 50 x 3010

1" x 2"

8 Ft

25 x 50 x 2255

Wall Studs Monsoon Window Joists Kitchen Wall Studs

2" x 2"

10 Ft

50 x 50 x 720

2" x 2"

10 Ft

50 x 50 x 450

2" x 2"

10 Ft

50 x 50 x 1285

Door Support

2" x 2"

10 Ft

50 x 50 x 2085**

Window Sill Shera wall cladding [SWC]

2" x 3"

10 Ft

75 x 50 x 3010**

8 x 200 x 3000

[see Cladding Section]

Ceiling Joists A

2" x 4"

10 Ft

100 x 50 x 3040

Ceiling Joists B

2" x 4"

10 Ft

100 x 50 x 3040

Ceiling Boards

1" x 8"

10 Ft

Gable Frame

2" x 2"

10 Ft

Gable Boards [SWC]

20 x 200 x 1000 12 [see Gable/Pre-structure Section]

8 x 200 x 3000

Purlins Purlin Gutter Support Purlin Cover [SWP] Shera roof Sheet Shera roof Sheet [Transparent] Kitchen Roof Support Kitchen Roof Shade [SWC] Shera Strip

[see Gable Section]

2" x 3"

14 Ft

75 x 50 x 4300

2" x 2"

14 Ft

75 x 50 x 4300

8 x 200 x 2150

8 x 200 x 3000

5 x 500 x 1200

50 x 50 3190

2" x 2"

12 Ft

8 x 200 x 3000

8 x 200 x 550

8 x 100 x 3000

8 x 100 x 668**

221

***Cut length to be double checked on site due to inconsistencies during process

5 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

BUILDING SEQUENCE 1

COLUMNS

GROUND BEAMS & TOP BEAMS

FLOOR & CEILING JOISTS

pg.14

RAFTERS

pg.20

FLOOR BOARDS & CEILING BOARDS

SECONDARY FRAME

pg.26

WALL STUDS, MONSOON WINDOW JOISTS & WINDOW SILL pg.32

WALL CLADDING

pg.36

PURLINS & GUTTER

10 GABLE FRAME & BOARDS pg.40

11 ROOF SHEETS

12 WALL PANELS pg.52

pg.44

pg.56

GROUPS & TASK SCHEDULE

Pre-structure Preparation

Cut Floor/Ceiling Joists

SMALL PANELS

Pg. 10

Pg. 20

Cut Wall Studs, Monsoon Window Joists, Window Sill

STRUCTURE SEQUENCE

Pg. 32

Cut Floor boards & Ceiling Prepare Secondary Frame Boards (Kitchen Frame)

Pg. 14

Pg. 56 -

Pg. 26 -

BIG PANELS

INSTALL FLOOR/CEILING JOSTS

INSTALL SECONDARY FRAME

Pg. 56

Pg. 20

Pg. 26

INSTALL FLOOR BOARDS & CEILING BOARDS

INSTALL WALL STUDS, M.W. JOISTS, WINDOW SILL

Pg. 20

Pg. 32

Pg. 36

Cut Door

Prepare/Cut Gable Frame & Boards

Prepare/Cut Purlins & Gutter

INSTALL WALL CLADDING

Pg. 44

Pg. 40

Pg. 36

INSTALL GABLE FRAME & BOARDS

INSTALL PURLINS & GUTTER

Prepare Roof Sheets

Pg. 44

Pg. 40

Assist leftover tasks

INSTALL DOOR

Assist leftover tasks

Prepare Wall Cladding

INSTALL ROOF SHEETS

Pg. 52

PRE-STRUCTURE PREPARATION MATERIAL CHECKLIST x6 Steel Parts x1 Column C2 x1 Column C4 x1 Roof Beam RB1 x1 Roof Beam RB2 x2 RAFTER x5 Timber [2 x 2 x 10ft] x2 Gable frame [2” x 2” x 980mm] x2 Gable frame [2” x 2” x 2900mm] x2 Gable frame [2” x 2” x 2870mm]

a b c

C2 C4 a b c

RB1 RAFTER

RB2

1 50

108

a 980

x2 COMPONENTS

2900

RB2 x2

12 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

RB1

RAFTER

1035

2870

c c

1495

STRUCTURE SEQUENCE MATERIAL CHECKLIST x20 Steel Parts x4 Column [ C1, C2*, C3, C4* ] x4 Ground Beam [ GB1, GB2, GB3, GB4 ] x4 Roof Beam [ RB1, RB2, RB3, RB4 ] x2 Foyer Beam [ T1, T1A ] x2 Truss [ T2 ] x2 Rafter w/ pre-installed timber x2 Typical Rafter x1 Timber [4 x 4 x 6ft] x2 Foyer Legs [4” x 4” x 675mm**] [ a ]

RAFTER* RAFTER

RB4 RAFTER*

RB1

C1 GB4

RB2

RB3 GB1

T1A

GB3

GB2

T1 T2

FOYER LEG

PRE-INSTALLED TIMBER

C1 ga

etw

olu

0 pla

n ce

r 00cente 31ter-to-

C3 d1

Bolt on outside

2 Nut on inside

GB1

GB3

15 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

3 C4 PRE-INSTALLED TIMBER

GB4

GB2

5 RB1 PRE-INSTALLED TIMBER

RB2 PRE-INSTALLED TIMBER

RB3

RB4

7 TYPICAL RAFTER TYPICAL RAFTER

RAFTER w/ PRE-INSTALLED TIMBER

T1A T2

T1 T2 a

x6 screws ~670

GROUND

double check on site

d1 19 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

JOIST & FLOORING SEQUENCE MATERIAL CHECKLIST x14 TIMBER [2 x 2 x 10ft] x1 Ceiling Joist [ 3000mm length ] a x13 Typical Joist [ 3040mm length ] b x4 TIMBER [1 x 8 x 10ft] x12 Ceiling Boards [ 1000mm length ] c x24 SHERA FLOOR PLANKS x16 Full 3000mm length d x16 1220mm** length e Leave one Typical Joist aside for Secondary Frame Team

3000mm

3040mm

b c

1000mm

x12 3000mm

d 1220mm

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x13

x16

x3 Philip screw

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2 b

3 d2

b x10

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last board will need to be cut in width

x16

first board in line with column

23 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

24 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

x16

50 50 50

x12

25 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

SECONDARY FRAME SEQUENCE MATERIAL CHECKLIST x16 Steel Parts x1 S1 x2 S2 x3 SB1 x4 SB2, SB3, SB4, SB5 x2 T3 / T3A x2 T4 / T4A x2 T5

T3 SB1

T3A

SB2

SB1 T4 T5

SB4

SB3

T4A

T3A S2 T3

1500

5mm GAP

d1 90°

SB4

ALIGNED! Make sure top & bottom brackets are aligned for wall studs!

28 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

3 T3

T3A

consult Joist/Flooring group for Ceiling Joist

SB1

SB5

ALIGNED!

T5 29 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

5 SB1 SB2 ALIGNED!

SB1 SB3

31 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

TIMBER STUDS SEQUENCE MATERIAL CHECKLIST x7 Timber [2 x 2 x 10ft] x12 Wall Studs [ 720mm length ] x6 Monsoon Window Joists [ 450mm length ] x4 Kitchen Wall Studs [ 1285mm length ] x1 Door Support [ 2085mm length ]

[ a ] [b] [c] [d]

x2 Timber [2 x 3 x 10ft] x2 Window Sill [ 3010mm length ]

[e]

32 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

b x6

a x6

33 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

3 100

30 800

800 100

x4 self-tap screws

WALL CLADDING SEQUENCE MATERIAL CHECKLIST x13 Shera Wall Cladding [8 x 200 x 3000] x8 Full size [3000mm] [ a ] x16 435mm length [b]

b x8 a x4

a x4 b x8

20 overlap 20 overlap 20 overlap ~15 overlap

a x4

b x8

38 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

20 overlap

~30 overlap

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PURLINS & GUTTER SEQUENCE MATERIAL CHECKLIST x1 Timber [2 x 2 x 14ft] x1 Purlin Gutter Support [ 4300mm length ] x7 Timber [2 x 3 x 14ft] x1 Purlin [ 4300mm length ]

[b]

x2 [SWC] Shera Wall Cladding [8 x 200 x 3000] x2 Purlin Cover [ 2150mm length ] x1 Gutter

40 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

[a]

[c]

1 a

MARK

575

41 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

3 GUTTER

4 b x6

575 575

x4 screws (confirm with Specialist)

c c

43 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

GABLE FRAME & BOARD SEQUENCE MATERIAL CHECKLIST x2 Timber [2 x 2 x 10ft] x1 Gable Frame A [ 2900mm length ] x2 Gable Frame B [ 880mm length ] x1 Gable Frame C [ 830mm length ]

[ a ] [b] [c]

x1 Timber [2 x 2 x 14ft] x1 Kitchen Roof Support [ 3190mm length ]

[d]

[SWC] Shera Wall Cladding [8 x 200 x 3000] x16 Kitchen Roof Shade [ 550mm length ] x7 Gable Cladding [ full 3000mm length ] x2 2700mm [g] x2 2300mm [h] x2 1870mm [i] x2 1500mm [j] x2 1050mm [k] x2 690mm [l] x2 280mm [m]

44 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

[e] [f]

x2 timber-to-steel screws

b b

45 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

L-Bracket

46 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

d Screw onto [ a ]

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e x16

48 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

5 35 overlap 35 overlap

f x5

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Overlap boards 25mm

a b c

d e

Overlap roof beam 30mm

95mm

a 710mm 635mm

b 1250mm 1125mm

c 1740mm 1665mm

d 2280mm 2205mm

e 2820mm 2750mm

3000mm

3000mm shera board 2205mm

710mm

a 2820mm

95mm 1250mm

1665mm

635mm

2280mm 1125mm

1740mm

135

c *

1740mm

1125mm 250mm 85mm

2750mm

115mm

3000mm

CUTTING GUIDE FOR COMPLEMENTARY SIDE 3000mm shera board 2205mm

710mm

e 2820mm

95mm 1250mm

1665mm

635mm

2280mm 1125mm

1740mm

135

c *

1125mm 250mm 85mm 115mm

1740mm 2750mm

f 3000mm

51 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

ROOFING SEQUENCE MATERIAL CHECKLIST x48 Shera Roof Sheet [White] x2 Shera Roof Sheet [Transparent]

Typical roof sheet Transparent roof sheet

5 4 3 2 1

3 Trilon Fastening Trilon can be used with both Steel and Wood Purlins without pre-drilling. To fix the Trilon tile, use Trilon Color Screw, a 4" self driven screw with neoprene washer as shown in the picture. (Fig.3) To fix Trilon color screw with Purlin, use a 5/16" hexagonal screw tip with screw driver and tighten properly. Trilon Color screw needs to be tightened properly, neither too tight nor too loose (please refer the picture). (Fig. 4). For steel purlin, use a minimum of 400 watt electric screw driver at the speed of 2,000-2,500 rpm. Neoprene Washer 4" Underdriven

Fig. 3

Correctly Driven

Overdriven

Fig. 4

4 Roof Structure Preparation Trilon tiles can be fixed well with both hard wood and metallic roof structure with a roof pitch of5325 to 40 degrees, (depending on ridge system used) Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd The Purlin size and type depend on the design code of each country. All purlins should be in one plane,

50mm overlap

54 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

200mm overlap

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PANELS SEQUENCE MATERIAL CHECKLIST x7 Large Panel Steel Frame [2000mm]

[ P1 ]

x8 Small Panel Steel Frame [1200mm]

[ P2 ]

x15 Steel Bar [674mm]

[ P3 ]

x14 Aluminium U-Channels [1920mm]

[ A1 ]

x16 Aluminium U-Channels [1120mm]

[ A2 ]

x56 Shera Strip [8 x 100 x 3000ft] x221 Panel Planks [ 668mm** length ]

[a]

A2 P2

57 Copyright ÂŠ 2013 EPIC Collaborative Sdn Bhd

a x11

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BIG PANELS P1 x5 screws

x19 planks