Building Technology 1: IBS System

Building Technology 1 [ARC 3512] Semester 5 Bachelor of Science (Hons) (Architecture) School of Architecture, Building and Design Taylor’s University

Industrialized Building System [IBS] Ahmed Iqbal Mohammed 1007P79864 Chloe Wong Choy Hoong 0310230 Edner Patrick Stephen 0314623 Mohammed Azif Sahadan 0309306 Nur-Sofia Mohamed Ghazemy 0314565 Wan Haziq Hilmi Wan Zainudin 0301918 Wan Izz Naufal Wan Ismail 1101P12392

Contents 1. IBS System a. Introduction 2. Taylor’s University a. Introduction i. Historical Background b. IBS Systems i. Slab System ii. Beam and Column System iii. Stairs System iv. Wall System c. Documentations 3. ‘Santa Madrona’ - 62 Social Dwellings a. Introduction b. IBS Systems i. Slab System ii. Beam and Column System iii. Stairs System iv. Roof System v. Wall System c. Model Building Documentation d. Documentations 4. Embodied Energy Calculations 5. Conclusion 6. Reference

1. IBS System a. Introduction Industrialized building system can be defines as a construction system which

5 Types of IBS System according to CIDB 1. Precast Concrete Framing, Panel and Box Systems which contain precast columns, beams, slabs, 3D components (balconies, staircases, toilets, lift chambers) 2. Steel Formwork Systems which include steel beams and columns, portal frames, roof trusses

components are manufactured in a factory, on or off site, positioned and assembled into structure with minimal additional site work. IBS was also defined as a construction system that is built using pre-fabricated components. The manufacturing of the components systematically done using machine, formwork and other forms of mechanical equipment. The components are manufactured off site and once completed it will be delivered to construction sites for assembly and erection.

IBS can be defined as a set of interrelated element that act together to enable the designated performance of the building. Industrialized building system also can be defined as a building system which involves industrialized production of building elements or components as well as erection and assembly of these elements into a desired building structure through

3. Steel Framing Systems which contain timber frames, etc.

4. Prefabricated Timber Framing Systems which contain timber frames.

Block work systems which contain interlocking concrete masonry Units, lightweight concrete blocks etc.

Advantages of using IBS System 1. High quality and good acceptance •

High quality-controlled products due to controlled environment in factory, better material

•

selection and using high mechanized technology.

of precast concrete multi-story framed building is now widely regarded as n economic,

•

Skilled workers with specific scope of works improve efficiencies and reduce errors.

structurally sound and architecturally versatile form of construction. It combines the benefits of

•

Unaffected by weather element due to controlled environment of casting area.

•

The industrialized building systems can reduce boredom and monotony by getting

mechanical and using as little in-situ construction as possible.

Precast concrete is one of the elements being associated with IBS construction. The use

very rapid construction and high quality materials with the advantage of production line economy and quality insurance. Design is carried out to the concrete industry and yet the knowledge

flexibility in architectural design.

remains essential within the precast concrete industry itself.

Precast construction are inherent in the precast beam to beam column connections, as these are jointed connection as opposed to cast-in-situ emulation type connection. This project

2. Cost •

Reducing on-site workers significantly reducing labor cost for contractors.

•

Minimizing cost of transferring waste material duo to quality control and reducing waste

is to investigate the behavior of the precast beam-to-column connection is as good as conventional cast-in-place connection. Connection design is one of the most important

material.

considerations for the successful construction of precast concrete structures. This is because the structural performance of precast concrete systems depends on the connection behavior.

Connection can be rigid (continuous design), semi rigid (semi continuous design) and

•

The ability to use the components' moulds repeatedly which made of steel, aluminum

•

Exemption of the Construction Levy for housing developers who utilize IBS components

simple. These terms indicate the degree of moment to be transferred between members. The rigid connection and simple connection transfer full moment and zero moment between members. The degree of moment transfer for semi rigid connection stands between rigid and simple connection.

No need to do rectification works because of closely checking and controlling in factory and this will save a lot of money.

3. Time •

Faster completion of projects due to advance off-site preparations and simplified installation process.

•

Manageable construction schedule by the use of planning control, estimated lead time and forecasted down time.

•

Off-site production can start while the construction site is under earthworks. This offers earlier

•

Occupation of building and minimizes interest payment.

4. Safety •

Promote safe and systematic factory working environment as minimal workers, materials and construction waste is required on-site.

5. Cleanness and neatness: •

IBS provide cleaner sites due to: -

Systematic components storage and timely material delivery (Just-in-Time principles).

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Reduction of construction material at site.

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Reduction of waste materials at site duo to casting in factory.

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Minimizing the use of formworks and props at site because of casting in factory.

1. Social benefits •

Reduce the dependency on foreign workers and reduce money outflow and their social problems,

•

low quality works, delays, and diseases.

•

Saving in labour at construction site about 40-50% compared to conventional method

2. Taylor’s University a. Introduction Taylor’s University Lakeside Campus encompasses a modern, functional design with state-ofthe-art facilities together with lush greenery and the trademark lake, striking a balance between form and function to embody the university’s modern approach and perspective in premium education with an approach to holistic growth outside the classroom.

Surrounding the lake are buildings that houses the academic blocks and the commercial annex that is comprised of wide and spacious corridors, pleasing and rich landscapes and all in all, a sustainable and conducive environment for education. The commencement of work for the RM 450 million campus in early 2007 is indeed an exciting phase in the 40 year old history of Taylor’s, and underscores its continued commitment to self development. It marks another major milestone for the institution, where great strides have been made since 1969.

The campus houses all existing tertiary programs under one roof. The campus received the prestigious PAM Gold Award in September 2011 from Pertubuhan Arkitek Malaysia (PAM) in Category 5 (Education) for the inspiring architecture and landscape design. The PAM awards is considered the premier architectural award in Malaysia, recognizing the best in architectural work. The new Taylor’s Lakeside Campus is a marrying of the philosophy and pillars of education with the architectural designs that takes into account the environment and community.

The campus has many types of facilities dedicated to the learning and teaching of its students including the ‘Art Precinct’, formed by the Experimental Theater, the 600-pax auditorium, 300pax lecture theater and an out amphitheater, staging plays, recitals and other performances. The pride of the campus is undeniably be the library, a splendid 4-story glass edifice that warrants panoramic views of the lake.

The beautiful Taylor’s Lakeside Campus will provide all the right conditions for a vibrant exchange between academic, commercial, social and leisure activities. More than just a home to the student population, it will be a nurturing ground for an energetic and dynamic new community. The campus is partially built using a

b. IBS Systems i. Slab System

Precast Concrete Slabs The most fully standardized precast concrete elements are those used for making floor and roof slabs.These may be supported by bearing walls of precast concrete or masonry or by frames of steel, sitecast concrete or precast concrete. Four kinds of precast slab elements are commonly produced. For short spans and minimum slab depts, solid slabs, are appropriate.

For longer spans, deeper elements must be used , and precast solid slabs, like their sitecast counterparts, become inefficient because they contain too much dead weight of non working concrete. In hollow-­core slabs, precast elements suitable for intermediate spans, of non working concrete. In internal longitudinal voids replace much of the nonworking concrete. For the longest spans, still deeper elements are required,and double tees and single tees eliminate still more nonworking

Double-­tee slab elements supported on a frame of precast columns and L-­shaped girders.

concrete (Allen. E & Iano.J., 2008).

Widths vary

2’, 4’, 8’ wide [610, 1220 2240mm ]

8’, 10’ wide [2440, 3050 mm ]

8’, 10’ wide [2440, 3050 mm]

Hollow-­core slab elements supported on precast concrete loadbearing wall panels

Slab to beam joining method

Floor slab supported by the beams in Block E, Level 4 of Taylors University

Short pieces of steel angle are welded to the plates to join the beams to the columns.

Smooth-­top hollow-­core precast concrete planks are placed on bearing pads on top of each beam. Grout is poured into the gap between the ends of the planks to unite loops of reinforcing that project from the tops of the beams, reinforcing bars that are inverted through the loops and lateral pieces of reinforcing bar that are grouted into the keys between planks. The end result is a tightly connected assembly that supports an untopped precast concrete floor or roof.

Topped hollow-­core roof slabs supported on beams are joined to a column with vertical rods. A similar connection can be used for floor beams resting on corbels

ii. Beam and Column System

Precast Concrete Beams, Girders, and Columns

Precast concrete beams and girders are made in several standard shapes. The projecting ledgers on L-­shaped beams and inverted tee provide direct support for precast slab elements.

They conserve headroom in a building by supporting slabs near teh bottoms of the beams, compared to rectangular beams without ledgers, where slab elements must rest on top.

AASHTO (American Association of State Highway and Transportation Officials) girders

were designed originally as efficient shapes for bridge structures, but they are sometimes were designed originally as e

used in buildings as well. Precast concrete columns are usually square or rectangular in

section and may be prestressed or simply reinforced (Allen. E & Iano J., 2008).

Beam to column joining method

The beams in this system of framing rest on concrete corbels that are integrally cast with the column. The smooth-­topped hollow-­core slabs are detailed for use without topping. Weld plates without topping. are cast into the column [picture on the left]. Beams are placed on bearing pads on the corbels. There is a weld plate cast into the top of each beam at the end [ picture on the right]

A posttensioned, structurally continuous beam-­column connection may be created by passing a tendon from a pocke in the top of one beam, through the column, to a pocket in the top of the other beam. The tendon is anchored to a plate in one pocket as it is tensioned by a jack in the other pocket

iii. Stairs System

Precast staircase Using precast staircases will shorten the construction duration. It also allows operational access instantly to all floor areas. When constructed as non-­critical structural components, stairwells can be used as access for the delivery of construction materials.

In practice, the number of risers and the riser height of a staircase have always been dictated by the storey height of a building. This would result in different riser dimensions.

Prefabricating stair flights with many different riser dimensions would not be economically viable. Design aspects related to the aesthetic, fabrication, handling and the erection of precast staircases were carefully considered and two distinct architectural features were incorporated in the standard precast concrete staircase: • Alignment of nosing of the first flight flushed with the nosing of adjacent flight.

• Simple and lined through intersection at the soffit of staircases where the flights and landings meet.

Isometric view of standard precast staircase [Dry joint]

Isometric view of standard precast staircase [Wet joint]

iv. Wall System

Precast Concrete Wall Panels

Precast concrete panels, either pre-­stressed or conventionally reinforced, are commonly used as loadbearing wall panels in many types of low-­ rise and high-­rise buildings. Solid panels typically range from 3.5 to 10 inches [90 to 250 mm] in thickness and can span one or two stories in height. When prestressed, strands are located in the vertical midplane of the wall panels to strengthen the panels against buckling and to eliminate camber. Ribbed or hollow-­core panels, or sandwich panels with integral rigid foam insulation, may be as deep as 12 to 24 inches [305 to 610 mm] and can span up to four stories (Allen. E& Iano.J, 2008).

Assembly of precast wall panels on site

A typical detail for the slab wall junctions in the structure. The reinforcing in the wall panels and the prestressing steel in the slabs have been omitted from these drawings for the sake of clarity

3. Santa Madrona - 62 Social Dwellings a. Introduction The case study is an apartment block located in Travessera de Dalt, Barcelona, Spain whereby

The buildings have been partially built with an industrialized building system, ensuring quality,

it deals with an affordable renting price. The total area of the two apartment blocks adds up to

deadlines and costs as well as promoting the production and innovation of the local industry. It is

5704 sqm dealing with an urban space, a small public square of the Gracia neighborhood of

also to ensure the control the consumption of resources, recycling and reusing. The structure is

Barcelona.

The homes, which are the separate units, have been designed and built with parameters of bioclimatic architecture, with an initial effort to reduce the demand for energy. Followed by detailed analysis and dimensioning of the facilities, introducing systems for producing renewable energy. There are a few main aspects considered in the design. All units utilizes natural crossventilation, which can be automatically or manually operated. The large balconies of the units ensure sun protection while all the rooms have been positioned and distributed evenly to ensure each home with the maximum natural lighting. The construction system for the facade include the highest guarantee of isolation. Other than that, the building harnesses the sun's heat energy for the preheating of the water to reduce gas consumption, ensuring sustainability of the building.

The sustainability of the building is increased through a command system whereby the system detects the presence of occupants in common areas to allow good distribution and optimization of the light use.

The design of the building is a straightforward form, a cuboid shaped building with balconies protruding out on the east and west facade. The layout of the building’s volume is a set of square on the chamfer, allowing the top corner of the street Travessera de Dalt with Escorial Street, bringing their own environment, a place of comfort in the middle of the city center. It is envisaged that the project that the natural comfort should be considered both in a city level and in the scale of the building.

set to be a heavy concrete structure with bearing walls, with supportive structures and facade simplifying the performance and its interior layout.

b. IBS Systems i. Slab System

Wide slab precast concrete is used for this project because of the the rapid solution to high quality, economical concrete floor construction where long spans and high load bearing capacities are require. The precast concrete floors are supported by the load bearing wall itself.

Individual precast floor units are manufactured in the long line prestressed system minimizing cost and production time.

The advantages of using the wide slab precast floors: •

Delivered to site ready to install and ready to use without costly site delays for curing.

•

Accurate first time placement. Means the floor plank is in its final position before the crane unhook

ii. Column System For this project, square precast concrete column is constructed on the ground floor and first floor(hidden in the wall). The precast concrete column is transported to site from factory and installed on the ground floors by incorporating with cast in place method used for ground floor slabs.

The advantage of using precast column system is: •

Precast column can be erected 5 times faster than an in situ column.

•

Ability to achieve a high quality and uniform finish

•

Unaffected by site weather and conditions

•

Reduction in labour requirement on site

•

Eliminates the need to small concrete loads and evening pours which are feature in-situ columns

•

When using high strength concrete, a reduction in reinforcement steel can be achieved.

•

The erection of precast concrete column is a silent process which can take place at any time

•

Eliminates noise of pouring and vibrating of in-situ column on site

iii. Stairs System Precast staircase system is used in this project. Precast staircase system is suitable to use for the residential staircase. The high quality finish gives a durable concrete staircase for a long maintenance free life. The dense precast concrete staircase gives an excellent acoustic properties such as sound transfer issues that associated with steel and wooden staircases. This type of stairs offers significant benefits during the construction phase of a project providing rapid installation and early safe access for the residential users.

The jointing systems of this precast is a dry joint construction. The precast staircase will be manufactured in the factory before it is brought over to site for installation. Before that, the special casting system ensures the concrete steps are produced from the steel mould face giving a uniform, smooth surface finish. Adjustable casting moulds enable concrete stairs to be precast with rising and going profiles to suit each application. Rapid steel mould adjustment without costly timber shuttering minimizes downtime and maximizing production

iv. Roof System Concrete decks used for planted areas can be waterproofed with either a concealed membrane or an exposed membrane. The type of planted roof type that is used is a light planted roof. Light planted rood has resilient plants that require little or no irrigation, and that will grow in a thin layer of soil or organic growing medium. Lightweight planted roof suit a lightweight concrete deck, such as thin concrete shell. Drainage beneath the growing medium that hold water and released it back to the plants when required.

Benefits of using planted roof system: •

Expand roof life up to 60 years

•

Reduce air-conditioning cost

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Reduce noise

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Improve aesthetics

•

Reduce energy demand.

v. Wall System Panel fixings are positioned near the corners, with slotted fixing used in order to allow for both thermal movement between the panel and supporting structure and also for adjustment during construction.

The joints have an outer open joint that is narrow and admits a small amount of rainwater, which is drained down and release back outside at the base of the panel through a stepped horizontal joint.

The cleats are typically fixed to a small channel fixing cast into the concrete. The panels are assembled by lifted into place by crane, using hooks and screwed into threaded tubes set into the crane typically on top or on the face of the panel. Lastly the hook are unscrewed when the panel is in place, and the holes plugged.

Panels are stacked with continuous vertical joints and are restrained by columns. The need to restrain panels on their vertical joint results in interlocking panel being long in order to optimize the distance between structural columns.

Since the stacked, interlocking panels have concrete on both sides, both horizontal joints and vertical joints usually have a limited thermal bridge. The thermal bridge can be avoided by the use of metal connection between two skins of concrete in place of a fully incased concrete panel.

Finishes used for the precast concrete panel is sandblasted finishes. Above is a picture of how sandblasted finishes is built on a precast concrete. This finish is achieved by casting the concrete against the precast panel with retarder to slow the set of the concrete on the surface.

After the form is removed, the retarded concrete is stripped away by sandblasting or with high pressure water to reveal the beauty and texture of the underlying aggregate in its natural color.

c. Model Building Documentation

Grey board is cut according to the plan of the building for each floor. This material is used to imitate the precast concrete material.

The staircase is cut out according to the plans, and assemble it as one en<ty to create a solid form of precast staircase.

Wire mesh is placed on the board to imitate a steel bar in the precast concrete.

Walls are put up according to the plans. The walls act as a precast wall manufactured in factory and assembled on site.

Precast walls are assembled by using an interlocking wall system where the wall is a?ached to one another to create a rigid structure that is also supported by the floors.

The connec<on grooves of the precast wall panels.

The bo?om of the panel is also designed in order to a?ached to the floors using the interlocking system.

Model grade gravel mixed is used to imitate gravel on the roof garden.

The precast column is prepared by layering the grey board to reach the column thickness.

Stairs are ready to be mounted to the landing.

Cork board is used to imitate the soil medium on the roof garden.

Precast floors and walls are in progress for comple<on of using the IBS system.

Assembly of roof garden

Exposed floor detail to express the materials and techniques involved

Assembly of roof garden

Usage of pad foo<ng as the founda<on detail

Roof garden details expressed through different layers of materials represen<ng a certain type of construc<on material

The comple<on of the assembly of the systems

d. Documentations

Precast concrete panel Horizontal joint (typically a lap) between panels

Precast concrete floor

Precast concrete floor

Precast wall

Precast concrete panel

Steel bar

Thermal insulation

Steel dowel

Thermal insulation

Smooth gravel

Grass Insulation layer Growing medium Drainage layer Cement layer Vapour barrier Concrete deck

Waterproofing layer

Vegetation

Smooth gravel

Thermal insulation

Growing medium Filter sheet

Wall clading

Drainage layer Waterproofing layer

Vapour barrier

Concrete deck

Steel bar

Concrete slab Diamond pour back

Base plate cover

RC Footing

4. Embodied Energy Calculations

Material

MJ/kg

Kiln dried sawn softwood

3.4

Kiln dried sawn hardwood

2.0

Air dried sawn hardwood

0.5

Hardboard

24.1

Particleboard

8.0

Medium density fiberboard (MDF)

11.3

Plywood

10.4

Glued laminated timber

11.0

Laminated veneer lumber

11.0

Plastics general

90.0

PVC

80.0

Synthetic rubber

110.0

Acrylic paint

61.5

Stabilized earth

0.7

Imported dimension granite

13.9

Local dimension granite

5.9

Clay bricks

2.5

Cement

5.6

Gypsum plaster

2.9

Plasterboard

4.4

Fiber cement

7.6

Insitu concrete

1.7

Precast steam-cured concrete

2.0

Precast tilt-up concrete

1.9

Concrete blocks

1.4

Autoclaved cerated concrete (AAC)

3.6

Glass

12.7

Mild steel

34.0

Galvanized mild steel

38.0

Aluminum

170.0

Copper

100.0

Zinc

51.0

Inputs

Length (m)

Area (m2)

Volume (m3)

Unit Mass (kg/m)

Density (kg/m3)

Mass (kg)

Energy Coeff (MJ/kg)

Embodi ed Energy (MJ)

Embodi ed Energy (MJ/m2)

Embodi ed Energy (MJ/m3)

Floor Slab System Precast Steam-cured Concrete

0.3 (thk)

128

38.4

2400

92160

2.0

184320

1440

4800

Ceramic Tiles

0.1 (thk)

12.32

1.232

2000

2464

12.0

29568

2400

24000

3840

28800

Total Embodied Energy Wall System Precast Steam-cured Concrete

0.3 (thk)

Glass Aluminum Frame

128

38.4

2400

92150

2.0

184320

1440

4800

0.01 (thk) 24

0.24

2000

480

12.7

6096

254

25400

0.1 (thk)

0.142

2700

383.4

170.0

65178

45900

459000

47594

489200

1.42

Total Embodied Energy Roof System Precast Steam-cured Concrete

0.3 (thk)

128

38.4

2400

92150

2.0

184320

1440

4800

Plastics

0.005 (thk)

100

0.5

1000

500

90

45000

450

90000

Stabilized Earth

0.15 (thk) 100

15

5520

82800

0.7

57960

579.6

869400

2469.6

964200

53903.6

1482200

Total Embodied Energy

Total Volume of Building Total Mass of Building Total Embodied Energy of Building

132.314 363087

5. Conclusion As a conclusion, the importance of learning and knowing IBS systems are very profitable especially in the case where the project involves rapid construction and limited construction period. However, based on the calculations of the Embodied Energy, we conclude that the usage of precast concrete forms produce high amounts of embodied energy, lowering the energy efficiency of the building. Even though the intention is that the building is to be sustainable during the occupancy stage, the construction materials gather large embodied energy amounts, being partially sustainable as an overall construction.

6. References 1. Hammond, G.P. and Jones, C.I. (2006). Inventory of (Embodied) Carbon & Energy (ICE), Department of Mechanical Engineering, University of Bath, United Kingdom.

2. Watts, A. (2010). Modern Construction Handbook: Second Edition. SpringerWienNewYork: Austria.

3. Allen, E. and Iano, J. (2009). Fundamentals of Building Construction; Materials & Methods: Fifth Edition. John Wiley & Sons, Inc: New Jersey.

4. Taylors.edu.my, (2014). Campus - About Taylor's : Taylor's University. [online] Available at: http://www.taylors.edu.my/en/university/about_taylors/campus

Therefore, the selection of materials for an IBS system is very crucial to ensure energy efficiency and to avoid any wastage of materials during the prefabrication stage, ensuring a sustainable building to be produced and constructed.

5. SPC Industries SDN BHD. [n.d.]. SPC Precast Beams. Retrieved from http://www.spcind.com/ usr/product.aspx?id=186 6. Unknown author. [n.d.]. Standard precast staircases. Retrieved from https://www.bca.gov.sg/ Publications/BuildabilitySeries/others/stdcom_ch3.pdf