Advanced Architectural Construction- Industrialized Building System Report

ADVANCED ARCHITECTURAL CONSTRUCTION INDUSTRIALISED BUILDING SYSTEM (IBS) PROJECT 1 STEEL FRAMING SYSTEM (ARC60104)

TUTOR : AR EDWIN CHAN YEAN LIONG PREPARED BY : GOAY CHING THENG 0332644 IZZATUL HANNIM BINTI SAIFUL ANUAR 0336568 KAN YEAN LIM 0336461 NURSHAZA NADHIRA ADILA BINTI SHAHRIAR 0337048 WINNIE TAY CHYI YING 0336223

CONTENTS 1.0 INTRODUCTION 1.1 1.2 1.3 1.4 1.5

AIMS AND OBJECTIVES TYPE OF INDUSTRIALISED BUILDING SYSTEM (IBS) ADVANTAGES & DISADVANTAGES OF IBS IBS PRECEDENT APARTMENT IBS PRECEDENT STEEL FRAMING SYSTEM

2.0 TECHNICAL DRAWING DESIGN 2.1 AXONOM ETRIC VIEW 2.2 FLOOR PLAN 2.2.1 GROUND FLOOR PLAN 2.2.2 FIRST FLOOR PLAN 2.2.3 SECOND FLOOR PLAN 2.2.4 ROOF PLAN 2.2.5 STRUCTURAL PLAN 2.2.6 FOUNDATION PLAN 2.3 ELEVATION 2.3.1 FRONT ELEVATION 2.3.2 BACK ELEVATION 2.3.3 RIGHT ELEVATION 2.3.4 LEFT ELEVATION 2.4 SECTIONS 2.5 M ODEL SEQUENCES

3.0 CONSTRUCTION SEQUENCES & DETAILS 3.1 IBS SEQUENCE 3.1.1 STEEL FRAM E STRUCTURE FOUNDATION 3.1.2 STEEL COLUM N 3.1.3 STEEL BEAMS

3.1.4 3.1.5 3.1.6 3.1.7 3.1.8

PRECAST HOLLOW CORE CONCRETE SLAB PRECAST WALL PANEL PRECAST STAIRCASE PRECAST TOILET PODS PREFABRICATED M ETAL ROOF TRUSS

3.2 IBS COM PONENTS DETAILS 3.2.1 JOINERIES OF STEEL BEAMS & STEEL COLUM NS & ROOF TRUSSES 3.2.2 JOINERIES OF STAIRCASE & STEEL BEAMS 3.2.3 JOINERIES OF I BEAM & HOLLOW CORE SLAB 3.2.4 JOINERIES OF PRECAST CONCRETE PANEL TO PANEL & STEEL COLUM N 3.2.5 JOINERIES OF STEEL COLUMN TO FOUNDATION

4.0 LEGENDS OF IBS COMPONENT 4.1 FOUNDATION 4.2 STEEL COLUMNS 4.3 STEEL BEAMS 4.4 PRECAST HOLLOW CORE SLAB 4.5 PRECASE WALL 4.6 STAIRCASE 4.7 PREFABRICATED M ETAL ROOF TRUSS 4.8 WINDOW 4.9 DOOR

5.0 IBS CALCULATIONS 5.1 STRUCTURAL SYSTEM 5.2 WALL SYSTEM 5.3 OTHERS SIMPLIFIED CONSTRUCTION SOLUTION (S)

6.0 REFERENCES

1.0 INTRODUCTION

1.1 AIMS & OBJECTIVES

AIM We are assigned a group assignment which predominantly relates to the topics of Industrialized Building System (IBS). We are also exposed to different types and methods of the IBS system and the calculation of IBS scoring. In this group, we are require to design a 3-storey apartment block using mainly Steel Framing System and was asked to make a digital model of the 3-storey apartment block. We are also assigned to make a report based on the apartment designed.

OBJECTIVES 1. To develop a clearer understanding in different types of IBS construction method.

2. To apply appropriate IBS construction method in the design of building.

3. To demonstrate a comprehensive understanding of IBS construction process through report writing.

4. To foster good communication skills among group members through proper delegation of works and production of deliverables.

1.2 TYPE OF INDUSTRIALISED BUILDING SYSTEM (IBS) Industrialized Building System (IBS) is a technique of construction whereby components are manufactured in a controlled environment, either at site or off site, and transported, positioned and assembled into construction works.

IBS can be divided into two systems: 1. Open system – using a combination of IBS components from different manufacturers 2. Close system – using only IBS components from one manufacturer IBS contains 6 different types which are:

Precast Concrete System

Prefabricated Timber System

Concrete mixing and curing are completed in a controlled casting environment therefore its quality can be consistent and less labor intensive.

Strength can be enhanced, preevaluated and assured, strength test is no longer required on site. It is also time saving for projects where preorder components are completed ahead, send to site for immediate installation. Weather has no longer a big factor to delays project, quicker completion of project gains more time value of money such as bank loan payoff, building handover, faster sales income recognition.

Prefabricated system is partial or complete assemblies which are then transported to the construction site as a result from component assembling done in plant or other factory, manufacturing site. Timber can be obtained easily, recyclable, cheap and design-friendly.

Timber manufacturer and supplier able to fabricate timber prefab beams, column, wood prefab wall, slab and roof panel for IBS project.

Steel Framing System Steel framing system in Malaysia allows load-bearing structure to be manufactured from controlled environment by various materials and assemble either on-site or offsite. Steel has long lifespan and resistance to rusting, molds and insects; its ductility, speed and safety features add points to why many developers choose to use prefabricated steel building materials in Malaysia.

1.2 TYPE OF INDUSTRIALISED BUILDING SYSTEM (IBS) Steel Formwork System Considered as one of the low-level or the least prefabricated IBS. The system generally involves site casting. Subject to structural quality control, the products offer high-quality finishes.

Temporary formwork used not less than 20 times. Steel formworks for concrete wall, beams and columns. Steel formworks are strong, durable and can be used for several times with advantage of installation and dismantling with in small time, so steel formworks are used in large construction works. In precast concreting process, these forms are used advantageously for repetitive casting operation.

Innovative System Combine multiple category of IBS, such as prefab with precast, blockworks with prefab, precast with brickwork to achieve better design, cost saving, energy efficiency and building friendliness to specific requirements by owners are very common nowadays in Malaysia too.

1.2 TYPE OF INDUSTRIALISED BUILDING SYSTEM (IBS) Blockwork System

I. Concrete Masonry Unit (CMU) Concrete Masonry Unit (CMU) supplier Malaysia has been doing well due to its versatility, easy to be installed and cost effective to builder. Its longevity, appealing finish, require no further treatment in term of paint makes it quick to build. It can also produce by natural green materials or recycled materials which does not have or contain low volatile organic compound (VOC).

II. Pavers Pavers flooring has many options in term of shapes, materials, colors and designs; it is often specified by Architect into landscaping and garden designs. It comprises of tumbled pavers, textured pavers and smooth pavers which are made by concrete, brick, rubber, bluestone, flagstone, travertine and cobblestone.

III. Interlocking Brick Interlocking brick is more convenient for builders without experience and skill set is not a constraint for this material, many developing countries in southeast Asia (SEA) such as Cambodia, Vietnam are popular due to its workability and low cost.

IV. Agricultural Waste Block It is defined as a agricultural waste made brick, block or panel which can be manufactured besides agriculture such as fly ash, wood, plastic, glass, rubber and others. These materials can be very low cost and at the same time get you green building (GBI) point.

V. Lightweight Block / Brick Malaysia’s lightweight block and brick are then expanded further into panel, supplier manufactures this type of cement masonry unit using lightweight aggregate. The best example is autoclaved aerated concrete (AAC), which is 1/5 of normal concrete.

1.3 ADVANTAGES & DISADVANTAGES OF IBS Advantages I. Less construction time • IBS requires less construction time because casting of precast element at factory and foundation work at site can occur simultaneously and the work at site is only the erection of IBS components. This leads to earlier occupation of the building.

II. Cost savings • The formwork of IBS components are made of steel, aluminum or other materials that allows for repetitive use and this leads to considerable cost savings.

III. Saving in labor • When the IBS components are produced in factory, higher degree of utilization of machine is permitted and the use of labor will be reduced and lead to saving in labor cost.

IV Less labor at site • The use of IBS will reduce the construction process at site and consequently reduce the number of labor required at site.

V. Optimized use of material • The utilization of machine during the production of IBS components lead to higher degree of precision and accuracy in the production and consequently reduce material wastage.

VI. Higher quality and better finishes • An IBS component have higher quality and better finishes due to the careful selection of materials, use of advanced technology, better and strict quality assurance control since production in factory is under sheltered environment.

VII. Construction operation less affected by weather • Faster project completion due to rapid weather construction. The effects of weather on construction operation are less due to the fabrication of IBS components is done in factory while at site is only erection of the components.

VIII. Flexibility • IBS provides flexibility in the design of precast element so that different systems may produce their own unique prefabrication construction methods.

IX. Increase site safety and neatness • Utilization of IBS components leads to less construction process especially wet work at site. This will lead to the neater site condition and increase safety.

X. Environmentally friendly • The use of IBS will decrease the using of timber formwork on construction project

1.3 ADVANTAGES & DISADVANTAGES OF IBS Disadvantages I. High initial capital cost • The initial capital cost of IBS is usually high. The initial cost including the cost of constructing the factory, casting beds and support machinery. The cost effectiveness can only be achieved when undertaking large projects.

II. Problem of joints • Water leakage is often the major problem in building constructed using IBS. This problem is more obvious in Malaysia where raining occur rapidly throughout the year.

III. Sophisticated plants and skilled operators • The prefabrication system relies heavily on sophisticated plants, which must be well coordinated and maintained by skilled operators. Breakdown in any one section would hold-up the entire production line.

IV. Site accessibility • Site accessibility is one of the most important factors of the implementation of IBS.IBS requires adequate sit accessibility to transport IBS components from factory to the site.

V. Large working area • Building construction using IBS requires a large working area for the factory, trailers, tower-cranes and storage for the IBS components. Besides, most construction sites especially in cities are often congested and unable to provide the area required.

1.4 IBS PRECEDENT APARTMENT Seri Mutiara Apartment Seri Mutiara is an apartment located in Setia Alam and designed

by Ar. Kiat Tung from T&T architect sdn bhd. The IBS system used in Seri Mutiara is the Precast concrete panel system. The Seri Mutiara apartment uses IBS system for construction due to the fast excavation on site. It uses precast staircase, precast wall (shear wall, load bearing and non-load bearing wall) and slab at bathroom. The contractor of Seri Mutiara apartment, Seri Precast sdn bhd at USJ precast yard fabricated the precast system and the design criteria that they used are according to the BS8110.

Total units: Built-up: Number of block: Number of units per level:

676 Approx. 939 sqft 6 12

1.4 IBS PRECEDENT APARTMENT Orthographic drawings of Seri Mutiara apartment:

Figure 1: Floor plan

1.4 IBS PRECEDENT APARTMENT

Figure 2: Precast concrete layout on plan

1.4 IBS PRECEDENT APARTMENT

Figure 3: Back elevation

1.5 IBS PRECEDENT STEEL FRAMING SYSTEM z-shape steel

Introduction of Steel Framing System Steel framing is generally based on the use of C or Z shaped steel sections produced by cold rolling strip steel. Cold formed sections are generically different from hot rolled steel sections, such as Universal Beams, which are used in fabricated steelwork. The steel used in cold formed sections is relatively thin, typically 1.0 to 4.0 mm, and its galvanized to corrosion protection.

Cold formed steel sections are widely used in many sectors of construction, including mezzanine floors, industrial buildings and hotels and have gained a significant market share in the residential sector. The main forms of construction include load-bearing frames. And infill walls to steel or concrete framed buildings.

Method of Construction The basic building elements of light steel framing are cold formed sections which can be prefabricated into panel or modules or assembled on site using various methods of connection. The different forms of construction are reviewed in the following sections.

In most systems, the walls are manufactured as storey-high panels of up to 3m length, shown in Figure 1.0.

The C sections are generally 80 to 150mm deep and are placed singly or in pairs at 600mm centres, depending on the required compression resistance of the wall.

The floors can be installed as individual sections of 150 to 300mm depth at 400mm or 600mm centres but they can also be manufactured as panels and supported on the walls as shown in Figure 1.1

Figure 1.0

Figure 1.1

C-shape steel

1.5 IBS PRECEDENT STEEL FRAMING SYSTEM Type of Method construction I. ‘Stick-build’ Construction This method of construction discrete members are assembled on site to form column, walls, rafters, beams and bracing to which internal lining and other elements are attached. The elements are generally delivered cut to length, with pre-punched holes, but connections are made on site using self-drilling, self-tapping screws, bolts, or other appropriate site techniques. This is less often used in larger buildings but can be used to self-build and other smaller projects.

II. Panel Construction Wall panels, floor cassettes and roof trusses may be prefabricated in a factory and later assembled on site. For accuracy, the storey-high panels are manufactured in purpose-made jigs.

Some of the finishing materials may be applied in the factory, to speed up onsite construction. The panels are connected using conventional techniques by using bolts or self-drilling.

1.5 IBS PRECEDENT STEEL FRAMING SYSTEM III. Modular Construction In construction wise, units are completely prefabricated in the factory and may be delivered to site with all internal finishes, fixtures and fittings. Units may be stacked side by side or one above another and connected to form the stable finished structure.

VI. Platform and ‘balloon’ Construction Panels may be assembled in either ‘platform’ or ‘balloon’ construction. In ‘platform’ construction, walls and floors are built sequentially one level at a time, so the wall are not continuously continued. In ‘balloon’ construction, the wall panels are much larger and are continuous over more than one storey. Such panels are more difficult to erect than single storey height panels and have to be temporarily braced whilst the floor are installed V. Infill Wall Construction Infill walls are built between floors of steel or concrete frames and designed to resist wind loading and to support the weight of the cladding.

It typically consist of 100mm deep C sections for walls up to 3m height and 150mm deep C sections for taller walls. Generally installed as individual elements within a top and bottom ‘track’ that allows for relative vertical movement.

2.0 TECHNICAL DRAWING

2.1 AXONOMETRIC VIEW

Axonometric Drawing Three-storey steel framing IBS system building apartment.

2.2.2 GROUND FLOOR PLAN

2.2.3 FIRST FLOOR PLAN

2.2.3 SECOND FLOOR PLAN

2.2.4 ROOF PLAN

2.2.5 STRUCTURAL PLAN

Hollow core slab Thickness: 200mm Width: 900, 1200, 1000mm Beam Thickness: 200mm

2.2.6 FOUNDATION PLAN

2.3 ELEVATIONS 2.3.1 FRONT ELEVATION

2.3.2 BACK ELEVATION

2.3.3 & 2.3.4 RIGHT ELEVATION & LEFT ELEVATION

2.4 SECTIONS

2.4 SECTIONS

2.5 CONSTRUCTION PROGRESS

2.5 CONSTRUCTION PROGRESS

3.0 CONSTRUCTION SEQUENCES & DETAILS

3.1 IBS SEQUENCE 1. Excavation Process of moving earth, rock or other materials with tools, equipment or explosives. Generally, excavation is carried out for the construction of wall foundations.

The Process are : ● ● ●

● ● ●

● ●

setting out corner benchmarks surveying ground and top levels excavation to the approved depth dressing the loose soil making up to cut off level the construction of dewatering wells and interconnecting trenches making boundaries of the building the construction of protection bunds and drains

3.1.1 STEEL FRAME STRUCTURE FOUNDATION 2.Construction of Steel Frame Structure Foundation Steel framed structure construction begins with the construction of its foundation. Precast concrete pilings are laid on the excavation site.

The Process are :

Reinforced concrete bearing pad Foundation for Steel Frame Structure.

Rebar work for Pad footing

3.1.2 STEEL COLUMN 3. Steel Column Construction The next step of steel frame construction is the placement of steel columns. The section of the steel is specified based on the load imposed.

Top bolt places created in base plate.

Side view of column base to foundation.

Concreting work for Pad footing

3.1.3 STEEL BEAMS 4. Erection of Steel Beams Beams commonly transfer loads from floors and roof to the columns.

Column to beam connection for the case where vertical loads are applied solely: Double angle cleat.

Full depth and extended end plat connection used when the column to beam connection subjected to both shear and torsion stress.

3.1.4 PRECAST HOLLOW CORE CONCRETE SLAB 5. Installation of Precast Hollow Core Concrete Slabs Floor slab is fitted to the beam. Then, Grouting is used for the precast concrete units after they have been placed in their position. Lastly, concrete topping on hollow core slabs by applying screed on it.

3.1.5 PRECAST WALL PANEL 6. Installation of Precast Wall Panels The precast concrete panel is placed on a corner of a wall using 2x4 bracing on both sides of the panel to support it until the next panels are attached. Then, line up the holes in the panel and press them together.

3.1.6 PRECAST STAIRCASE 7. Installation of Precast Staircases Precast staircases were used and being joined by the concrete rebate to the landing.

3.1.7 PRECAST TOILET PODS 8. Installation of Precast Toilet Pods The precast toilet pod are placed inside the apartment. It is connected to the floor slab.

3.1.8 PREFABRICATED METAL ROOF TRUSS 9. Installation of Prefabricated Metal Roof Truss The prefabricated metal roof truss is connected with the bracing material to make truss-to-truss connections and then clips to attach the truss to the bearing member.

Determines the size of the roof truss

Roof Tiling

Build the roof truss

Attach roof truss to the frame

3.2 IBS COMPONENT DETAILS 3.2.1 STEEL BEAMS & STEEL COLUMNS & ROOF TRUSSES

A. RIDGE

C. JOIST BEARING AT UPPER FLOOR

B. EAVE

B

D. INTERIROR JOIST BEARING

A

F E. JOIST PARALLEL TO END WALL

C

D

F. GABLE END FRAMING

E

3.2.2 STAIRCASE & STEEL BEAMS

3.2.3 STEEL BEAM & HOLLOW CORE SLAB

3.2.4 PRECAST CONCRETE PANEL TO PANEL & STEEL COLUMN

3.2.5 STEEL COLUMN TO FOUNDATION

4.0 SCHEDULE OF IBS COMPONENT

4.1 FOUNDATION

4.2 STEEL COLUMN

4.3 STEEL BEAMS

4.4 PRECAST HOLLOW CORE SLAB

4.5 PRECAST WALL

4.5 PRECAST WALL

4.5 PRECAST WALL

4.6 STAIRCASE

4.7 PREFABRICATED METAL ROOF TRUSS

4.8 WINDOW

4.9 DOOR

5.0 IBS CALCULATIONS

5.0 IBS CALCULATION

5.1 STRUCTURAL SYSTEM

Floor

Area (m2)

IBS Factor (Fs)

Coverage (Qs/Qst)

Ground Floor : Steel beams + steel columns + precast hollow core slab

325.2 m 2

1.0

325.2/1300.8 =0.25

0.25x1x50 =12.5

Level 1: Steel beams + steel columns + precast hollow core slab

325.2 m 2

1.0

325.2/1300.8 =0.25

0.25x1x50 =12.5

Level 2 : Steel beams + steel columns

325.2 m 2

1.0

325.2/1300.8 =0.25

0.25x1x50 =12.5

Roof : Prefabricated metal roof trusses

325.2 m 2

1.0

325.2/1300.8 =0.25

0.25x1x50 =12.5

1.0

50

Total:

1300.8 m2

IBS score

Table 1. IBS Factor for Structural Systems

5.2 WALL SYSTEM

Table 2. IBS Factor for Wall Systems

Wall

Length (m)

IBS Factor (Fs)

Coverage (Qs/Qst)

External wall: Precast concrete panels

273.6 m

1.0

(273.6/508.2) = 0.54

0.54 x 1.0 x 20= 10.8

Internal Wall : Precast concrete panels

234.6 m

1.0

(234.6/508.2) = 0.46

0.46 x 1.0 x 20= 9.2

Total:

508.2

1.0

IBS score

20

5.3 OTHER SIMPLIFIED CONSTRUCTION SOLUTIONS(S) 2. Repetition of Structural Layout

Unit

Coverage

IBS score

Unit

Coverage

IBS score

100% of column usage follow MS1064 Part10:2001

Nos

100%

4

Repetition of floor to floor height

Nos

100%

2

100% of beam usage follow MS1064 Part10:2001

Nos

100%

4

Vertical repetition of structural floor height

Nos

100%

2

4

Horizontal repetition of structural floor layout

Nos

100%

2

4

Total

1. Utilization of Standardized Component Based on MS1064

100% of wall usage follow MS1064 Part10: 2001

100% of floor slab usage follow MS1064 Part10: 2001

m

m2

100%

100%

IBS Score for Project (Part I + Part 2+ Part 3)

100% of door usage follow MS1064 Part 10:2001

Nos

% of windows usage follow MS1064 Part 10:2001

Nos

4 100%

4 100%

30 100

6.0 REFERENCES Aathaworld Sdn Bhd .(2020) .Industrialized Building System (IBS).

Retrieved from : https://www.aathaworld.com/industrialized-building-system-ibs Adto mall .(2008). Steel Formwork System. Retrieved from: http://www.adtomall.com/steel-formwork Inepar Triunfo Sistemas Construtivos. (2014, July 1).An Innovative System Construction.

Retrieved from https://www.youtube.com/watch?v=szhDT3n23ec M.Wollam. (2015, November 20 ). Excavation Construction. Wollam Construction.

Retrieved from: https://wollamconstruction.com/excavation-construction/ .

The Constructor Civil Engineering Home ( n.d.). Construction of Steel Frame Structure Foundations, Columns, Beams and Floors.

Retrieved from: https://theconstructor.org/structures/construction-steel-structure-foundations-columns-beams-floors/18648/ S.Gupta. (2014, Apr 4) . Steel Roof Trusses. Retrieved from: https://www.slideshare.net/Dudesid1/steel-roof-trusses

E.Yandzio, R.M. Lawson, A.G.J.Way.(2015).Light Steel Framing In Residential Construction. SCI (The Steel Construction Institute).

Retrieved from: https://www.steelconstruction.info/images/2/23/SCI_P402.pdf What is IBS . (n.d). Retrieved from: https://mummyku.weebly.com/uploads/5/2/5/4/52547687/ibs_topic_1.pdf Construction of Steel Structure 2012.(2012).

Retrieved from: http://www.ekt.bme.hu/ArchEng/Construction%20of%20steel%20structures%202015.pdf Manual for IBS Content Scoring System.(n.d.).Perpustakaan Negara Malaysia Cataloguing-in-Publication Data.

Retrieved from: http://cm609.yolasite.com/resources/IBSScore.pdf

The Concept of Light Gauge Steel Framing Construction.(n.d.)

Retrieved from: https://www.wiley.com/legacy/products/subject/architecture/archdesign/constructioneducation/chapter/pa ge1.htm