Building Technology I : Industrialized Building System

Building Technology 1 Project 1 : Industrialised Building System (IBS)

Group Member Cheok Kahying Loi Chi Wun Ng Zien Loon Ng Jing Yuan Sim Li Mei

Tutor 0328560 0328652 0328565 0331472 0328623

Mr. Khairool

1

CONTENT LIST

1.0 Introduction 1.1 Industrialized Building System (IBS) 1.2 Types of IBS in Malaysia 1.3 Proposed IBS System (Precast Concrete System) 1.4 Case Study 1.4.1 Ikea Batu Kawan, Penang 1.4.2 High End Boutique Bungalow, Bukit Damansara 1.4.3 Single Storey Semi-D Temerloh, Pahang 1.4.4 UITM Dewan Annexe, Shah Alam

3.0 IBS Components 4 5 6 7 8 9 10

2.0 Proposed Design 2.1 Architectural Drawings 2.1.1 Plans 2.1.2. Elevations 2.1.3 Sections 2.2 Structural Drawings 2.2.1 Structural Foundation Plan 2.2.2 Structural Floor Plans 2.2.3 Structural Roof Plan 2.2.4 Precast Floor Slab Arrangement Plan 2.3 Exploded Isometric 2.4 Schedule of IBS Components 2.4.1 Precast Column 2.4.2 Precast Beam 2.4.3 Precast Hollow Core Slabs 2.4.4 Precast Wall 2.4.5 Precast Blockwork 2.4.6 Precast Staircase 2.4.7 Prefabricated Doors 2.4.8 Prefabricated Windows 2.4.9 Prefabricated Steel Roof Trusses

11 12 16 20 22 23 26 27 28

3.1 Overview of IBS Components 3.2 Sequence of Construction 3.3 Cast in-Situ Pad Foundation 3.4 Precast Column 3.5 Precast Concrete Beam 3.6 Precast Concrete Hollow Core Slab 3.7 Prefabricated Toilet Pod 3.8 Precast Wall Panels 3.9 Blockwork 3.10 Precast Concrete Staircase 3.11 Prefabricated Steel Roof Truss 3.12 Dry Wall Systems

40 41 44 45 47 49 51 52 53 54 56 58

4.0 IBS Score Calculation

59

5.0 Conclusion

63

6.0 References

64

29 30 31 32 34 35 35 36 37

2

1.0 INTRODUCTION

1.1 INDUSTRIALIZED BUILDING SYSTEM (IBS) Introduction Industrialized Building System (IBS) is a technique of construction that uses components that are manufactured in a controlled environment. The IBS components are either on site, off site, transported, positioned and assembled into a structure with minimal additional site work.

The Construction Industry Development Board (CIDB) was formed in 1994 and they function to promote the usage of IBS system in Malaysia construction industry.

There are two systems of IBS which are open IBS or closed IBS. Open IBS system refers to the usage of combination of prefabricated building components from different companies and the components are compatible and interchangeable with each other in building project. Closed IBS system refers to specific components that can only be used in specific projects by certain manufacturers.

Modular Coordination (MC) is a standard of measurement for IBS elements to coordinate the dimension and spaces of the building. It provides provision of proper metrical building planning, design, construction, installation and manufacturing of building components in accordance with MS 1064.

Advantages of IBS Decrease in construction cost By repeating the usage of steel and aluminium formwork, it would reduces the construction wastage.

Reduce manual labour needs The fabrication process occuring off site at the manufacturing factory in a controlled environment.

Increase productivity Construction duration can be reduced as the process of casting components can happened off site.

Increase quality of building components The fabrication process in a controlled environment ensure the quality control of the building components.

Disadvantages of IBS Increase in initial costs High initial costs due to the need of special machine to cast the components Expensive for small scale projects Suitable for large scale projects that require mass production Low supply and require sufficient space for storage Local construction industry has yet to be developed with not much manufacturer and supplier available.

Required skilled labours The construction process required trained worker.

IBS Workframe

Design Consideration IBS components need to be designed based on the specification stated in MS 1064.

Manufacturing The building components are built according to the standard dimensions and in modules at factories in controlled environments.

Delivering to site The completed IBS components will be delivered to the site.

Assembly on site The building components are positioned and assembled on site using machineries.

Completion Finishes such as plastering and painting are done to add aesthetic value to the completed unit.

4

1.2 TYPES OF IBS IN MALAYSIA

Blockwork system Blockwork components consists of concrete blocks that interlock or lightweight which produced a lightweight structure with better insulation characteristics.

Precast Concrete system Precast concrete system are made up of components which are prefabricated in the factory by casting the concrete in the formwork. The components available include concrete columns, beams, slab, walls and more.

Steel Framing system Steel framing system are widely used in large span buildings and factories. The system consists of steel beams and columns, portal framing system and roof trusses.

Prefabricated Timber Framing System Timber frame components are produced off site in factory. It has high aesthetic values and are cost efficient. This system consists of timber frames, beams, columns and roof trusses.

Formwork System Formwork system are modular formwork for in-situ concrete. The system consists of permanent steelwork forms, beams and column moulding forms and more. It reduces the number of site labour and materials, time and provide high quality finishes.

Innovative System Innovative system also known as refers to the combination of 2 or more IBS systems that uses other systems to utilise the advantages and minimizes the disadvantage of the systems.

5

1.3 PROPOSED IBS SYSTEM

Precast Concrete System

Introduction of Precast Concrete System

Staircase

Precast concrete system is used as the main IBS system for the proposed apartment building.

Precast concrete system is the group that is most widely used in the IBS. It includes precast concrete columns, beams, slabs, walls, “3D” components, lightweight precast concrete, as well as permanent concrete formworks. General contractors find the use of precast concrete components make their job easier at the site, ensuring a smooth process for the owner and designer in both the short and long terms. There are fewer trades to coordinate with precast construction.

To speed up site production, stair flights can be of precast instead of cast in-situ concrete.

Precast concrete system is use as the main supporting system while steel framing system and blockwork system also implemented in the project respectively at walls and roof components.

Cast In Situ Components Foundation Ground Beam Ground Slab Precast Components Column Beam Hollow-core slab Staircase Prefabricated Components Steel roof truss Windows & doors Railings

Precast concrete wall systems offer a wide variety of shapes, colors, textures, and finishes to the designer. As a result, the assessment of samples is a key component in the use of precast concrete. The majority of the review and approval process is conducted at the precast plant prior to precast panel production. This assessment is in addition to the quality control and field testing that takes place during the production phase.

Typically, each precast panel is independently supported to the building structure using an assemblage of metal components and anchors. Joints around each of the precast panels are usually filled with sealant.

Components of Precast Concrete System

Hollow Core Planks Precast hollow core flooring units provide long spans with cross-sections that reduce the height of the building, saving material cost, and their inorganic composition enhances fire protection.

Double Tee Slab These components provide excellent roof and flooring units, spanning considerable distances and providing quick erection to close in a structure faster.

Wall Panel Architectural precast wall panels are the solution of choice for the cladding on many office buildings, institutional facilities and mixed-use retail projects of all types.

Blockwork Systems Lightweight block work Beam and Column Additional Components Toilet pods

The use of precast columns and beams makes an ideal framework for hanging precast panels, creating a design that offers fast construction, structural stability and enhanced fire resistance.

6

1.4 CASE STUDY - PRECAST COLUMN & BEAM 1.4.1 IKEA BATU KAWAN, PENANG

Types of Building Components Used

Construction Process

1. After the completion of construction preparation, the layout of the structure is set.

Then, the foundation of the columns are constructed.

Precast Column

2. Columns are placed on top of the foundation.

Architect : Arkitek Rekawasan IBS system : Concrete Formwork IBS Components : Precast Column, Precast Beam IBS Manufacture : Eastern Pretech Malaysia Introduction Precast Beam

The new IKEA store in Batu Kawan, Penang, is one of the first developments to proceed on this greenfield site. While IKEA Batu Kawan is notable for its fully modular precast construction, which has earned an impressive industrialised building system (IBS) score of 92.3 out of 100. Fabricated off site, the structural components were put together with the help of hoisting machines and teams of lifting supervisors and signalmen. This resulted in less site labour and wastage, as well as better quality and safety, saving both construction time and cost. EP Precast System optimizes the level of industrialization by:

3. Precast beams and precast floors in the case of large panel systems and column slab are placed.

Beam to Column System ● ● ●

Transferring work off-site to a controlled factory environment enabling consistent quality products; Advocating modular and standardized works to simplify construction works; and Working simultaneously at the factory and the site to shorten construction time.

IBS Factor [ Reference : CIS 18:2018 ] Components

IBS Factor

Analysis

[Concrete Formwork] Precast Columns and Beams

0.8

Full IBS Factor

4. After the installation of precast concrete beams, precast concrete floors are erected.

Above steps is applied up to 3 floors.

7

1.4 CASE STUDY - BLOCKS WALLS & PRECAST CONCRETE SLAB 1.4.2 HIGH END BOUTIQUE BUNGALOW, BUKIT DAMANSARA

Types of Building Components Used

Proven Company Precast Concrete Slab ● ● IBS System : Wall System , Concrete formwork IBS Components : Engineering blocks, precast concrete slab IBS Manufacture : Proven Malaysia Sdn. Bhd Introduction The construction of high end boutique bungalow using Proven IBS at Bukit Damansara, Kuala Lumpur. The Proven Holding SDN.BHD has been active since 1994, holds PKK Class A and (CIDB) (G7) contractor and is registered with the government of Malaysia. The company has made itself very relevant in the field of IBS.

● ● ● ● ●

Certified IBS product by CIDB and SIRIM Quality Control with G40 mix with high strength prestressed wire Slab thickness is 50 mm Slab modular width is 200 mm and 400 mm Slab length up to 5 to 5.4 metres 50 mm Grade 30 structural topping with wire mesh Thinner slab eases handling and transportation

Proven Company Engineering Blocks ● ● ● ● ● ● ● ●

Patented in Malaysia Load Bearing Wall Certified IBS product by CIDB Quality Control with G25 mix Manufactured Average Compressive Strength is 7N/mm2 2 hours of fire rating by SIRIM and BOMBA Special tongue and groove features for easy installation and self alignment Air gap feature for good heat and sound insulation

Construction Process

IBS Factor [ Reference : CIS 18:2018 ] Components

IBS Factor

Analysis

[Wall System] Load Bearing Block Wall

0.5

Full IBS Factor

Precast column & beam + precast concrete slab

1.0

Half IBS Factor

1. Fabrication process of concrete slab including casting beds, attaching wires, pouring concrete and cutting slabs are done at factory.

2. Engineering blocks as well are precasted at factory, process including dosing, ringsing, casting and cutting before load to the site.

3. Precast concrete slab are placed on the foundation.

Wall is erected with blocks and rebar for reinforcement.

4. Upon completion, finishes are applied act as a protection for the blocks.

8

1.4 CASE STUDY - PRECAST CONCRETE WALL 1.4.3 SINGLE STOREY SEMI-D TEMERLOH, PAHANG

9 days of Construction Works

[Day 1]

[Day 2]

[Day 3]

Grid level precast wall panel installation and filling of expanding cement.

Grid level expanding cement filling, wet joint rebar, modular mould installation & concreting.

Grid level wet joint rebar, modular mould installation.

[Day 4]

[Day 5]

[Day 6]

IBS System : Wall System IBS Components : Precast concrete wall IBS Manufacture : HC Precast System Sdn. Bhd Introduction A testing for government housing 4.0 agenda for IBS for Superstructure Works to complete 2 units of single storey semi-d houses in 9 days with 9 workers.

Industrialized Building System (IBS) Superstructure Specialist 100 % Malaysia Technology With 6 IPs’ Green Building : There’s 3 uniques in 1 System : Monolithic Load Bearing Wall, Modular Wet Joint System (Shear Keys), Box System

Car porch column rebar, modular mould and precast beam installation, car porch column concreting.

Wet joint modular mould dismantle, precast half slab & in-situ modular mould installation for RC flat roof .

In-situ modular mould installation for RC flat roof at car porch. Roof level precast wall panel installation

IBS Factor [ Reference : CIS 18:2018 ] Components

IBS Factor

Analysis

[Wall System] Precast Concrete Panel

1.0

Full IBS Factor

[Day 7]

In-situ slab rebar & BRC installation. Roof level precast wall panel installation.

[Day 8]

Roof level wet joint rebar & modular mould installation.

[Day 9]

Roof level wet joint concreting. All support to beam will be dismantle after 14days as comply to BSI code.

9

1.4 CASE STUDY - PREFABRICATED STEEL ROOF TRUSS 1.4.4 UITM DEWAN ANNEXE , SHAH ALAM

Construction Process

IBS System : Roof Structural System IBS Components : Prefab metal roof trusses IBS Manufacture : Kemuning Structures Sdn Bhd Introduction UITM Dewan Annexe has used K-Structures™ Lightweight Steel Truss System from Malaysia. They are formed using High-Tensile Galvanized or Zincalume® channels and purlins. Lightweight Roof Truss System can be easily fabricated and assembled on site especially for steel trusses with long span where transportation is a major problem.

The simplicity of the lightweight steel truss makes it an easy task to be carried out by skilled workers. With no painting required for lightweight roof truss system, the actual construction period is thus shortened.

STEP 1: Examine the entire set of fabrication and Architectural drawings.

STEP 2: Referring to the Roof Framing Layout, mark out truss positions on the top plate.

STEP 3: Begin by installing the gable end truss.

STEP 4: Use two hex head tek screws through the fixing bracket at each heel connection into the side of the top plates once the gable truss is in position.

STEP 6: As per Steps 4 and 5 install the next truss in its set-out position and temporarily brace the truss at or near the apex.

STEP 7: Continue procedures in

positioning

trusses

as

per

the

STEP 8:. With the flush end towards apex, install Gable Frames. Gable frames will sit on top of the Gable truss and butt into the face of the first standard truss.

STEP 5: Temporarily brace the gable truss plumb and straight.

IBS Factor [ Reference : CIS 18:2018 ] Components

IBS Factor

Analysis

[Roof Structural System] Prefab Metal Roof Trusses

1.0

Full IBS Factor

10

2.0 PROPOSED DESIGN

2.1 ARCHITECTURAL DRAWINGS

W2

W2

W4

W4

W2

W2

W2

W2 W2

W2

W2

W2 W4

W5

W4

W1

W5

W1

W5

W5 W4

W4

W3

W3

W5

W2

W5

W5

W2

W2

W2

W5

LEGEND W - Precast Concrete Wall Ground Floor Plan | Scale 1:100

12

2.1 ARCHITECTURAL DRAWINGS

W2

W2

W4

W4

W2

W2

W2

W2 W2

W2

W2

W2 W4

W5

W4

W1

W5

W1

W5

W5 W4

W3

W3

W5

W2

W5

W5

W2

W2

W2

W5

LEGEND W - Precast Concrete Wall First Floor Plan | Scale 1:100

13

2.1 ARCHITECTURAL DRAWINGS

W2

W2

W4

W4

W2

W2

W2

W2 W2

W2

W2

W2 W4

W5

W4

W1

W5

W1

W5

W5 W4

W3

W3

W5

W2

W5

W5

W2

W2

W2

W5

LEGEND W - Precast Concrete Wall Second Floor Plan | Scale 1:100

14

2.1 ARCHITECTURAL DRAWINGS

Roof Plan | Scale 1:100

15

2.1 ARCHITECTURAL DRAWINGS

South Elevation | Scale 1:100

16

2.1 ARCHITECTURAL DRAWINGS

North Elevation | Scale 1:100

17

2.1 ARCHITECTURAL DRAWINGS

East Elevation | Scale 1:100

18

2.1 ARCHITECTURAL DRAWINGS

West Elevation | Scale 1:100

19

2.1 ARCHITECTURAL DRAWINGS

Section A-A’ | Scale 1:100

20

2.1 ARCHITECTURAL DRAWINGS

Section B-B’ | Scale 1:100

21

2.2 STRUCTURAL DRAWINGS

Ground Floor Structural Plan (Foundation Plan) | Scale 1:100

22

2.2 STRUCTURAL DRAWINGS

C5

C5

C1

C1

C1

C1 C2

C5

C2

C5

C2

C2 C2

C2

C2

C2

C2 C4

C2

C4

C2

C2

C3 C3

C3

C3

C3

C3 C3

C3 C1

C1

C3

C3 C2

C2

C2

C2

LEGEND C - Precast Concrete Column First Floor Structural Plan | Scale 1:100

23

2.2 STRUCTURAL DRAWINGS

C5

C5

C1

C1

C1

C1 C2

C5

C2

C5

C2

C2 C2

C2

C2

C2

C2 C4

C2

C4

C2

C2

C3 C3

C3

C3

C3

C3 C3

C3 C1

C1

C3

C3 C2

C2

C2

C2

LEGEND C - Precast Concrete Column Second Floor Structural Plan | Scale 1:100

24

2.2 STRUCTURAL DRAWINGS

C5

C5

C1

C1

C1

C1 C2

C5

C2

C5

C2

C2 C2

C2

C2

C2

C2 C4

C2

C4

C2

C2

C3 C3

C3

C3

C3

C3 C3

C3 C1

C1

C3

C3 C2

C2

C2

C2

LEGEND C - Precast Concrete Column Roof Level Structural Plan | Scale 1:100

25

2.2 STRUCTURAL DRAWINGS

SRT4

SR T3

T3 SR

SR T1 SR T3

T3 SR

T1 SR

SR T3

T3 SR

SRT5

T2 SR

SR T2

SRT6

T2 SR

SR T2

T2 SR

SR T2

T1 SR

SR T1

T1 SR

SR T1

LEGEND SRT - Steel Roof Truss Roof Truss Structural Plan | Scale 1:100

26

1

SL

1

SL

2

2

SL 1

SL

1

1 SL

1

1 SL

1

SL

1

SL

SL

1

SL

SL

1

SL

SL

SL 2

SL 2

SL 2

3

3 SL

SL

3 SL 3 SL 3 SL 3 SL 3

1

SL

3 SL 3 SL 3 SL 3 SL 3 SL

SL

1

SL

1

SL

3 3

SL

3

3

3

2

SL

2 SL

2 SL

2 SL

2 SL

3

SL

SL

SL

SL

3

SL

3

SL

SL

1

SL

1

SL

1

SL

1 SL

1

SL

1

3

3 SL

3

SL

SL

3

3

3 SL

1

SL

1

SL

SL

1

SL

1

SL

SL

1

SL

3

3

3

1

SL

3

SL

SL

SL

SL

SL

SL

1 SL

1

1

SL

SL

1

2.2 STRUCTURAL DRAWINGS

LEGEND SL - Precast Concrete Floor Slab Precast Floor Slab Arrangement for First Floor and Second Floor | Scale 1:100

27

2.2 STRUCTURAL DRAWINGS

Exploded Isometric | Scale 1:150

28

2.4 SCHEDULE OF IBS COMPONENTS PRECAST COLUMN

Component

Columns C1

C2

C3

C4

C5

Isometric

3500

3500

10500

3500

3500

Plan 300

260

Quantity System

18

300

300

500

40

500

36

300

395

460

6

300

4

Structural System

29

2.4 SCHEDULE OF IBS COMPONENTS PRECAST BEAMS

LINTEL

Compone nt

Beam

B1

Lintel

B2

L1

Isometric

150

Plan

150

1050

System

Structural System

Quantity : 10

30

2.4 SCHEDULE OF IBS COMPONENTS PRECAST HOLLOW CORE SLABS

Component

Slabs SL1

SL2

Isometric

150

150 150

Plan

4500

4500

4500

Section 150 900

Quantity System

90

150 600

150 700

120 Precast Concrete System

31

2.4 SCHEDULE OF IBS COMPONENTS PRECAST HOLLOW CORE SLABS

Component

Slabs SL1

SL2

Isometric

150 150

Plan

4500

4500

Section 150

150

900

Quantity System

600

90

120 Precast Concrete System

32

2.4 SCHEDULE OF IBS COMPONENTS PRECAST WALL

Component

Walls W1

W2

W3

W4

Isometric

150

150

150

150

Plan

3050

1700

Quantity System

6

3050

700

3050

450

24

3050

1700

6

18

Precast Concrete Panel

33

2.4 SCHEDULE OF IBS COMPONENTS PRECAST WALL

Component

Walls W5

W6

W7

W8

Isometric

150

150

150

150

Plan

3050

2350 1600

1600

2700

2700

4

4

2700

900

Quantity System

12

4

Precast Concrete Panel

34

2.4 SCHEDULE OF IBS COMPONENTS BLOCKWORK [WALL]

Component

Blockwork BL1

BL2

Isometric

190 190

Plan 150

150

150

300

Quantity System

2312

705 Block Work System

35

2.4 SCHEDULE OF IBS COMPONENTS PRECAST STAIRCASE

2.4.7 PREFABRICATED DOOR

Component

Staircase

Door

ST1

D1

Isometric

175

2100

Plan

900 3800

200

1050 280 1000

Quantity System

4

30

Precast Concrete System

Prefabricated Door

36

2.4 SCHEDULE OF IBS COMPONENTS PREFABRICATED WINDOW

Component

Windows

Lintel

W1

W2

L1

Isometric

3050

1200

150

150

Plan 150

1800

Quantity System

150

1050

750

24

18 Prefabricated Windows

37

2.4 SCHEDULE OF IBS COMPONENTS PREFABRICATED STEEL ROOF TRUSSES

Component

Steel Roof Trusses SRT1

SRT2

SRT3

Isometric

Section

175

Quantity System

100

4

175

100

8

105

75

6

Prefabricated Steel Framing

38

2.4 SCHEDULE OF IBS COMPONENTS PREFABRICATED STEEL ROOF TRUSSES

Component

Steel Roof Trusses SRT4

SRT4

SRT6

Isometric

Section

100

150

Quantity System

1

100

100

80

1

1

Prefabricated Steel Framing

39

3.0 IBS COMPONENTS

3.1 OVERVIEW OF IBS COMPONENTS

Overview of IBS Components

Precast Concrete System Precast concrete system is used as the main IBS system for the proposed apartment building.

Additional Components Toilet pods

Cast In Situ Components Foundation Ground Beam Ground Slab

Prefabricated Components Steel roof truss Windows & doors Railings

Blockwork Systems Lightweight block work

Precast Components Column Beam Hollow-core slab Staircase

41

3.2 SEQUENCE OF CONSTRUCTION

1.

Excavation

Excavation of site according to the strip footing layout offset of the interior and exterior walls

4. Beam Assemble of Precast beams together with Precast columns

2. Foundation Cast in-Situ Pad Foundation is casted on site of the excavated land

5. Precast Hollow Core Slab Precast hollow slab are placed accordingly. The slab panels are secured by reinforcement bars from the vertical hollow block walls and then cast secured with concrete

3. Column Erection of Precast Columns on top of the Pad footing

6. Staircase Placing of concrete steps by crane on top o the slab and butt the steps against the building

42

3.2 SEQUENCE OF CONSTRUCTION

7. Floor Precast hollow slab are placed accordingly. The slab panels are secured by reinforcement bars from the vertical hollow block walls and then cast secured with concrete

10. Blockwork Precast concrete blockwork are built on top of the hollow core slab as an infill between the superstructures.

Reinforcement bars are placed at each hollow core to connect all blocks vertically.

8. Toilet Pod -

Prefabricated toilet pod is then slot into the spaces before the walls are erected

9. First Floor Repetition of step 3 to 10 on the first floor

9. Precast Concrete Wall The precast concrete panels are prefabricated in the factory and then assembled on site

10. Second Floor Repetition of step 3 to 10 on the first floor

43

3.2 SEQUENCE OF CONSTRUCTION

11 Doors. Windows

12. Steel Roof Trusses 13. Metal Roof

Prefabricated Doors and Windows are installed in between the openings of the blockwork walls

Diagonal steel roof trusses ensure strength and compressive strength towards the building

Metal roof panels are then bolted onto the steel truss structures

14. Dry Wall Installation of dry wall panel using t-braces to hold it in place. Panel running vertically from the floor to the ceiling

44

44

3.3 CAST IN SITU PAD FOUNDATION Introduction

Construction Details

Construction Method : Cast in situ Construction Material : Reinforced Concrete (with rebars) Cast in situ pad foundation is a type of foundation that support point loads from concrete columns and ground beams. Without overstressing the ground which the pads rest on, the pads distribute load from the column to base of the pad. Constructed on site, this pad foundation is connected to the precast concrete columns by bolted connection. Anchor bolts are used for this bolted column connection to transfer tension, compression and shear forces from the precast columns to the pad foundation. The columns are cast in with the bolt counterparts which are the column shoes at a precast factory.

A crane operator is required during installation process.

In our case, precast concrete frame system are selected as the main supporting system of the apartment which create point loads to the ground hence cast in situ pad foundation with anchor bolting is suitable.

Anchor bolts and steel-end plates or column-shoes are used for this bolted column connection to transfer tension, compression and shear forces from the precast columns to the pad foundation.

Construction Process: 1.

2.

3.

4.

5.

6.

Preparation of formwork Cast in situ the concrete for pad foundation and column stump The foundations installed on pre-levelled washer and nuts After curing, nuts are tightened with hand tools.

The crane support is then released.

The gap are filled with high-strength grouts to provide support and prevention of corrosion to the nuts that would reduce the strength of whole structure.

Advantages 1.

2.

3.

Easy and fast erections : Eliminate need for on-site welding and temporary bracings during the installation of columns on the pad foundation Moment stiff connection : Able to support superior loads from structures as soon as the nuts are tightened and also resist high stresses during construction.

Simple connection : Does not require complex connections and also reduce excavation depth and costs.

Cross section of the cast in situ pad foundation below ground level foundation.

Section and plan view of the foundation

45

3.4 PRECAST COLUMN Introduction Construction Method : Construction Material : Reinforced Concrete (with rebars)

Process of Fabrication Precast (1) Placement of reinforcement bars into position

(2) Sufficient spacers with correct sizing is properly placed and secured before casting.

(3) Mould of columns - formwork are assembled.

(4) The level and flatness of the base mould is checked before assembling the mould.

Precast concrete column is a load bearing element that used to support beams and slabs as a structural system. To provide resistance to bending forces, the precast concrete columns may be prestressed with four to six steel rebars for additional compression and tensile strength. Corbels are used to distribute the load and to support the weight of beams.

In our proposed 3-storey apartment, 300mm x 300mm column size is chosen with reference to MS 1064 guidelines of preferred sizes for reinforced concrete components.

Advantages 1.

2.

3.

Efficient construction : faster installation, shorter construction period High quality : good quality can be achieved as prefabricated in controlled environments Sustainable construction : reduced wastage on site due to casting in factory ; elimination of formworks and temporary supports at site

(5) Pouring of vibrating concrete

concrete

and

(6) Smoothen the concrete with slider and appropriate curing time is observed and environment controlled

46

3.4 PRECAST COLUMN

Bolted Connections for Column-column connections

Construction process: 1.

The column is lowered in place and the nuts are tightened to specified torque with hand tools. This precast column-to-column connection are moment-resistance.

2.

A crane operator and two people on the ground is needed to complete this on-site installation process with each column require 20 minutes.

3.

With the high strength grout filled at the gap of joint which held the anchor bolt, the connection is completely formed.

20mm diameter anchor bolts

Grout

300mm x 260mm precast concrete

The precast column is with rebar to give higher strength to the concrete.

Metal bearing plate are embedded anchor bolts are cast on the end of the columns. Metal Shim is used to level up the space and fill gap between two objects.

The upper column section with the bearing plate fixed are attached to the anchor bolts from pile cap are tightened and the nuts are also hammered. Welding provided at connection to prevent unwanted movement.

After the joint part is held in place, the bolted joint part are jointed with high-strength cement grout to avoid the components from fire and corrosion exposure.

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3.5 PRECAST BEAM Introduction Construction Method : Precast Construction Material : Reinforced Concrete (with rebars)

Process of Fabrication

(1) Placement of reinforcement bars into position

(2) Tension cables are laid

Precast concrete beam is horizontal components that support deck members such as the slabs and sometimes other beams.

They are generally three key shapes for beams which are rectangular, inverted tee beams and L-beams.

(3) Anchor grips for cables are inserted and tensioning of cable is formed.

In our proposed 3-storey apartment, L-beams and rectangular beams are chosen with reference to MS 1064 guidelines of preferred sizes for reinforced concrete components.

(4) The stoppers are sealed.

(5) The mould of concrete are laid

Advantages 1.

2.

3.

4.

(6) Anchoring system are activated

Good and consistent quality : the components are produced in controlled environment hence the construction component quality can be maintained.

Durability and seamless integration : required very little maintenance and it does not require additional fire proofing.

Time and cost saving : the production of component off site allowed faster installation on site.

Better noise control : The density of precast beams allow better noise control between floor to floor.

(7) Pouring of machinery help.

concrete

with

(8) Curing of concrete and the moulding surface is cleaned.

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3.5 PRECAST BEAM Construction Process 1.

Reference Line is set before prestressed concrete beams are erected according to framing plans. Framing plans show a plan view of the beams with their markings. Erection mark is painted or stamped on to show where each beam s to be placed.

2.

3.

Cranes and wire ropes are used to lift the beam to into place and lower them onto the bearings. Coincidence of the centerline of the beam with centerline of bearing is verified.

Intal and lap the rebars as required for beams which have cast-in joints.

4.

Set up the formwork for the casting of joint

5.

carry out concrete casting and remove forms after sufficient concrete strength has reached.

Weld plate cast into beam

Bearing pads on corbel Construction Detail (Beam to Column)

Stirrup

Prestressed tendons Welded plates

300mm x 300mm precast concrete column

corbel

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3.6 PRECAST CONCRETE HOLLOW CORE SLAB

Introduction Construction Method : Precast Concrete System Construction Material : Reinforced Concrete IBS Factors : 0.8 (Full IBS Factor) Process of Fabrication Precast hollow core slab or simply a concrete plank is a precast slab of prestressed concrete system. It is one of the most broadly and often utilized as precast concrete flooring system in a building structural system. Ordinarily, it is an extruded concrete process and gives specialists such as engineers and architects a flexible precast concrete system for creative construction.

(1) Preparation of Casting Beds

(2) Prestressing

(3) Concrete Distribution

Batching

and

The precast concrete slab has tubular voids extending the full length of the slab, typically with a diameter equal to the 2/3-3/4 the thickness of the slab. It is known to be quick and convenient to assemble on site with phenomenal lower surface finishes and industrial facility guaranteed quality, offers building consultants the various advantages for value added construction.

In our case, the application of component for the apartment functions as a service ducts while reducing the self-weight of a slab and helps maximizes the structural efficiency.

(4) Casting

(5) Detailing

(6) Curing

Advantages 1.

2.

3.

4.

5.

Large Span Length : Tubular and hollowed-out voids reduces self-weight and number of beams and columns while increasing valuable space Thinner deck : Ability to span large lengths while also possesses a decreased depth ratio where space savings is achieved compared to traditional floor and ceiling systems Fire Resistance : Prestressed hollowcore slabs possess an inherent fire resistant quality and significantly resist the movement of fire High Sound Resistance : Material provides sound absorption feature resists impact of sounds such as footsteps, airborne, voices and others Weather Resistance : The strength and durability seen from controlled environment manufacturing guarantees a product highly-resistant to the wear and tear of severe weather.

(7) Detensioning

(8) Cutting

(9) Stripping of Beds

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3.6 PRECAST CONCRETE HOLLOW CORE SLAB Construction Process 1.

2.

3.

4.

The hollow core slabs are placed on bearing pads of precast beams.

Reinforcement bars are inserted into slab keyways to span the joint.

Grout is filled into the gap between the ends of the slabs of the joint with the beam.

The hollow core concrete slab may remain unfinished or finished with thin layer of cast in situ concrete.

Connection of Slab to Interior Beam

upper slab reinforcement

Construction Detail Slab to Beam Connection

connection rebar precast beam

reinforcement bar

Connection of Slab to Perimeter Beam

upper slab reinforcement

precast concrete beam

precast hollow core slab

connection rebar precast beam

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3.7 PREFABRICATED TOILET POD Fabrication and Construction Process Introduction Parmarine prefabricated bathroom modules are a system of ready-made bathroom located as separate units within a building structure. The bathroom modules come complete with sanitary equipment, lighting fixtures and piping, as well as ready-made connection to the water and sewerage networks. The modules are manufactured with dimensions and plumbing equipment that is customized to the individual building project. A Parmarine bathroom module with floor area of 5m² and weighs approx. 2000 kg.

Reinforced concrete slab embedded into floor frame , wall constructed of steel studs

Advantages 1.

Good standards and workmanship water-tightness 2.

Shorten construction period, as factory can proceed production in parallel with the worksite activities

Main components and materials included in the modules.

wall tiles steel stud with pvc laminate

seal with polyethylene sealing strip

silicon

Roof construct with holes for connection of ventilation system

silicon seal with polyethylene sealing strip

floor tiles silicon

wall tiles

Interior wall finishings applied and fixtures installed

reinforced concrete slab

sealant steel stud with pvc laminate

Wall and Ceiling Wall construction consists of 400mm wide steel studs of 0.8mm thick epoxy coated steel sheets that are riveted together. Internal surfaces consist of ceramic tiles. The waterproofing between the wall cassettes is made with two polyethylene sealing bands. The roof construction consists of uninsulated cassettes of 0.8mm thick steel plates.

Delivery to site for installation

Floor Consists of a reinforced concrete slab embedded in a frame of galvanized steel. Flooring is covered with a plastic membrane and ceramic tiles, alternatively with vinyl coating (PVC). The water seals between the wall elements and the flooring are carried out with a polyethylene bonding strip Unpackage and external wall finishings applied

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3.8 PRECAST WALL PANELS Introduction Process of Fabrication Construction Construction

Method :Precast Concrete System Material : Reinforced Concrete

Precast concrete wall panels offer design flexibility, time savings and improved profitability.

Joints between panels must be wide enough to accommodate thermal expansion and differential movements between panels. The joints between wall panels are usually sealed with sealant to provide waterproofing characteristics reducing possibility of decrease in strength due to water penetration in the wall cavity. On the other hand, water resistant membrane used to cover the wall cavity space and back up wall, providing a secondary line of protection against the water penetration.

(1) Reinforcement bar is laid and the splice are tied together

(2) Hold the reinforcement cage in place

In our case, precast concrete wall panels are used as the ease of installation and reduced construction time. Non-load bearing wall panels are used as the wall panels are not required to carry the load from the framed supporting system.

(3) Smoothen the concrete with slider manually

(4) Reinforcement cage is placed into the formwork

(5) Pouring of concrete evenly with help of vibrator

(6) Final smoothing of concrete with trowel before curing of concrete.

Advantages 1.

2.

3.

Energy saving : excellent R-value (insulation properties.

Superior strength and durability : does not deteriorate over time and require less maintenance Aesthetically pleasing : Allow variety of finishes applied to the wall panel to achieve the desired appearances.

Construction Process:

1.

2.

3.

4.

Align panel to the desired position in accordance to the architectural drawings.

In general, the permanent connections, such as mild steel dowel bars of size 16mm diameter and mild steel angle are fixed into the concrete beams top and bottom respectively.

A gap of minimum 20mm is provided at the top between ceiling and panel and in-fill with polystyrene foam for vertical movement.

All vertical joints is sealed with jointing compound in accordance to manufacturer’s procedures and instructions.

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3.9 BLOCKWORK Introduction Construction Method : IBS Construction Material : Concrete IBS Factors : 0.5 (Half

Process of Fabrication Blockwork

System

of

Factor)

IBS

(1) Preparation of raw materials

(2) Batching and mixing

(3) Moulding and forming of concrete mix

(6) Packaging

(7) Distribution

External non-load bearing hollow block wall is made up of standard sizes of hollow blocks. Mortar of lightweight aggregate material are used to fill the voids of the hollow concrete blocks. Voids of ¼ gross area and the solid area should be not less than half of its area of the hollow concrete blocks to attain its maximum allowable load capacity.

Different needs of different types of structures require the structure and the composition of the concrete blocks to be varied. Different ratio of raw materials such as cement, aggregate and water produced blocks of different compressive strength.

(5) Curing of concrete with kiln

In our case, non-load bearing hollow block wall are selected as the wall system of the apartment. As externally exposed wall, hollow concrete blocks are preferred choice due to its better resistance to rain penetration than solid blocks hence allowing it to be left as unfinished surfaces. The mortar joints need to be fully filled and tooled to prevent moisture ingress and to increase its durability.

Advantages 1.

2.

Types of blockwork

3.

High durability: Compacted by high pressure and vibration which increase strength of blocks and ability to withstand a high level of loading. The blocks are with high fire resistance and no salinity that decreases their maintenance cost.

Cost effective : Cheaper cost of construction material.

Speedy construction: Uniform sizes and shape and its lightweight properties reduce construction time.

Construction Detail Infill Hollow Blocks to Precast Wall and rest on Beam As an infill materials with no load-bearing function. The addition of rebar and mortar infill of voids are exempted. Only cement mortar is used to bind the concrete hollow blocks together and jointment with precast hollow wall panels and resting beam.

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3.10 PRECAST CONCRETE STAIRCASE Introduction Construction Construction

Process of Fabrication Method :Precast Concrete System Material : Reinforced Concrete

(1) Setting up of timber formwork

(2) Layering of reinforcement bars with correct positioning

To accelerate site production, stair flights can be of precast rather than cast in-situ concrete. Precasting stairs delivers better surface completions, avoids the inherent problems of casting complicated inclined sections on site and provides rapid access to successive floors. As precast concrete needs no additional curing on site and does not require protection from weather conditions, as well as acoustic insulation.

The main components of a precast concrete staircase consists of : staircase flights, landings and steps. The components are manufactured in the factory together with the connections being fabricated along with the stairs to ease the assembly process on site.

The reinforcement bars were added directly through the fabrication process to strength the compressive strength of the staircase.

The installation process on site is quick, neat, clean and dry. It usually takes place after the main superstructures are completed. With recesses are left opened at the supporting slabs or beams to prepare to receive the prefabricated staircases.

(3) Pouring of vibrating concrete

concrete

and

(4) Compact and spreading evenly of concrete

In our case, precast concrete staircase helps minimises the whole life cycle impact on environment when compared with other construction materials. Being stable throughout its life, precast concrete is a inert substance and will not emit any gaseous or toxic compounds affecting the occupants.

Advantages 1.

2.

3.

4.

5.

Cost Effective : simplified construction process reduces time, increases productivity, quality and safety Time Consuming : as it does not require additional curing on site and skillful labour compared to cast in situ or timber staircase Flexible Finishes : Allow additional finishes being constructed with other materials such as timber or stone Space Saving : because it does not require fabrication space at site Durability : Precast concrete has high strength and durability as it will lasts longer comparing to timber

(5) Curing of concrete to form solid stairs slab

(6) Lifting of casted stairs and deliver to site

55

3.10 PRECAST CONCRETE STAIRCASE

Construction Details Infill structural screed

shims

Precast landing to precast concrete staircase connection

tie bar

tie bar

shims

Infill structural screed

PC stairs

landing landing

Precast landing to precast concrete staircase connection 1

PC stairs

Precast landing to precast concrete staircase connection 2

Hole from PC stairs Infill structural screed PC stairs

Precast landing to precast concrete column connection

landing

angle bolted into wall

shims Precast concrete staircase to ground floor slab connection

Ground floor slab

precast concrete column Dowels drilled to foundation

Precast landing to precast concrete column connection

Precast concrete staircase to ground floor slab connection

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3.11 STEEL ROOF TRUSS

Fabrication Process

Introduction Construction Method : IBS Prefabricated Construction Material : Steel IBS Factors : 1.0 (Full

Steel of

Framing IBS

System Factor)

(2) Installers used to arrange members before fastening them together.

(3) Align truss members using inverted stools

(4) Fasten the screws at the bottom chord and web members

(5) The apex joint are fastened with screws

(6) The added stiffening members may require box up

(7) Assembly of trusses according previous truss

(8) Move to storing area

(1) Create a truss template

Prefabricated steel roof truss is a lightweight roof system which offers high strength that can be installed very fast on site. In comparison with timber roof trusses, prefabricated steel roof truss capable to provide longer life span due to its resistance to termite.

In our case, the prefabricated steel roof trusses is suitable due to its lightweight properties which reduced the load imposed on pad foundation applied in our system besides it can be installed fast and easy during construction.

Advantages 1.

2.

3.

High strength to weight ratio : High strength to weight ratio of steel in comparison to concrete. It can withstand high stress situation.

High durability : The steel member size is uniform and remain stable and require minimum maintenance.

Good fire resistance : Fire-retardant coated steel roof trusses virtually indestructible by fire.

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3.11 STEEL ROOF TRUSS Construction Process

1. Using a crane to lift up the steel roof truss onto the position 2. Secure the steel roof truss anchor bolt onto the roof beam 4. C-channel purlins are welded onto the roof trusses.

5. Roof sheathing layers are placed on top of the purlins layer by layer.

Metal roof decking

C-channel purlin Insulation foam

Steel Roof Truss

Construction Detail (Roof Truss to Roof Beam)

Steel Roof Truss

Roof Beam

Steel Roof Truss

Sill Plate

Concrete Beam

Anchor bolt

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3.12 DRY WALL SYSTEMS Introduction Construction Method : IBS Dry Construction Material : Composite panel IBS Factors : 1.0 (Full of

Wall

System

IBS

Factor)

Construction Process (1) Set the wall position for floor tracks and wall studs

(2) Install 1st board

Dry wall system is made of fibre cement boards fixed onto galvanised steel stud and track frames. Insulation materials such as mineral wool improve acoustic, heat and fire resistant of the wall. The cost-efficient and innovative construction method In our case, dry wall system made of cement boards with mineral wool as insulation material are chosen due to its strong physical strength and fast erection that save construction time. This method is hassle-free and produce low wastage and space efficient.

Advantages 1.

2.

3.

Fast & lightweight : construction time is 5 times faster than brick walls Simple construction method : Less stiffeners required and can be erected in dry condition without need of cement mortar plastering Strong & secured : Drywall has higher physical strength due to it has double cement board structures

(3) Fix M&E services wool,install board

&

add

mineral

(4) Flush jointing,patching of fastener

Construction Details Galvanised Steel U-channel Top Track Galvanised Steel C-channel Studs

(5) Finishes

Galvanised Steel Nogging Mineral Wool Fibre Cement Board

Galvanised Steel U-channel Bottom Track

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4.0 IBS SCORE CALCULATION

4.0 IBS SCORE CALCULATION

ELEMENTS

AREA (m²) / LENGTH (m)

IBS FACTOR

COVERAGE (%)

IBS SCORE

PART 3: Other Simplified Construction Solutions Utilisation of Standardised Components Based on MS 1064 - Beams (80) - Columns (80) - Slabs (80) - Doors (100)

Repetition of Structural Layouts - Repetition of floor to floor height - Vertical repetition of structural floor layout - Horizontal repetition of structural floor layout Other Productivity Enhancing Solutions - Usage of prefab bathroom units (PBU) - Usage of prefab staircases - Usage of BIM models for IBS Score submission - Usage of Modular grid lines in drawings

60% 60% 60% 100%

2 2 2 4

100% 100% 100%

2 2 2

100% 100% 100% 100%

2 2 6 4

TOTAL PART 3 IBS SCORE (PART 1 + PART 2 + PART 3)

30 86.25

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4.0 IBS SCORE CALCULATION

ELEMENTS

AREA (m²) / LENGTH (m)

IBS FACTOR

COVERAGE (%)

IBS SCORE

(287m² /1148m²) = 0.25

0.25 x 0.7 x 50 =8.75

(287m² /1148m²) = 0.25

0.25 x 1.0 x 50 =12.5

PART 1: Structural Systems Ground Floor - Precast column & in situ beam + In Situ Concrete on Permanent Formwork

287m² (105 + 105 + 77)

0.7

First Floor - Precast column & beam + precast concrete slab

287m² (105 + 105 + 77)

1.0

Second Floor - Precast column & beam + precast concrete slab

287m² (105 + 105 + 77)

1.0

(287m² /1148m²) = 0.25

0.25 x 1.0 x 50 =12.5

1.0

(287m² /1148m²) = 0.25

0.25 x 1.0 x 50 =12.5

Roof truss using prefab steel

287m² (105 + 105 + 77)

1148

TOTAL PART 1

46.25

PART 2: Wall Systems External wall using precast blocks Internal wall using dry wall system

426.3

246m

0.5

(246m / 426.3m) = 0.58

0.58 x 0.5 x 20 = 5.8

180.3m

1.0

(180.3m / 426.3m) = 0.58

0.42 x 0.5 x 20 = 4.2

TOTAL PART 2

10

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4.0 IBS SCORE CALCULATION

ELEMENTS

AREA (m²) / LENGTH (m)

IBS FACTOR

COVERAGE (%)

IBS SCORE

PART 3: Other Simplified Construction Solutions Utilisation of Standardised Components Based on MS 1064 - Beams - Columns - Slabs - Doors

Repetition of Structural Layouts - Repetition of floor to floor height - Vertical repetition of structural floor layout - Horizontal repetition of structural floor layout Other Productivity Enhancing Solutions - Usage of prefab bathroom units (PBU) - Usage of prefab staircases - Usage of BIM models for IBS Score submission - Usage of Modular grid lines in drawings

60% 60% 60% 100%

2 2 2 4

100% 100% 100%

2 2 2

100% 100% 100% 100%

2 2 6 4

TOTAL PART 3 IBS SCORE (PART 1 + PART 2 + PART 3)

30 86.25

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5.0 CONCLUSION

In conclusion, the 3-storey apartment with an IBS score of 86.25% has managed to reach optimum score of the use of IBS system. The precast components used in the building adhere to the standard dimensions according to MS 1064. The IBS components that was implemented are the precast columns, precast beam, precast hollow core slabs, precast wall panels, hollow block wall and prefabricated steel roof truss.

We have a better understanding on IBS construction methods and its advantages as well as disadvantages. It is time saving and require less labour at the same time providing high quality of buildings which are more durable.

The physical model making process enables us to have a chance to carry out hands-on process which at the same time allows us to be more clear on the installation and construction sequences.

We were able to propose a three storey apartment which mostly composed of IBS components. We also now have deeper understanding and knowledge towards the IBS construction system and the implementation method of the system in this construction industry in Malaysia.

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6.0 REFERENCES

Buildability Development Section, Technology Development Division of the Building and Construction Authority. (1999). Architecture in precast concrete. Singapore.

Compiled by Legal Research Board. Uniform Building By-Laws 1984, 1997, International Law Book Services, Kuala Lumpur.

Eatern Pretech, N. S. L. (n.d.). Retrieved from http://www.epmsb.com.my/pro_ep.asp.

Elliott, K. S. (2018). Precast concrete structures. Boca Raton: CRC Press.

Engström, B. (2008). Structural connections for precast concrete buildings. FIB: Commission C, 6.

Earthquake Resistance Test Of Scaled Down Double Storey Building By Hc Precast System In Collaboration With Utm, Johor Based On 8 Major Earthquakes, In The World. (N.d.). Retrieved From Http://www.hcprecast.com/v2/.

Minera Roof Trusses. (n.d.). How to Build Roof Trusses. Retrieved from https://www.minera-rooftrusses.com/roof_trusses_build.html.

Pods. (n.d.). Retrieved from https://www.rollalong.co.uk/pods/.

Portal Rasmi CIDB. (n.d.). Retrieved from http://www.cidb.gov.my/.

Prefab Column to Column Connection. (n.d.). Retrieved from https://civildigital.com/prefabricated-structures-prefabrication-concept-components-advantages-ppt/column-to-column-connection/.

Toscas, J. G. (2008). Designing with precast and prestressed concrete. Chicago: PCI Bookstore.

UTHM Follow. (2014, July 8). Presentation ibs. Retrieved from https://www.slideshare.net/finalistfarrah/presentation-ibs?from_action=save.

Stirane, A. (2017). ways to connect precast columns to foundation.

Schembri, J. (2019 , May 20 ). Precast column anchoring systems. Retrieved from http://ias.com.mt/precast-column-anchoring-systems/ Mazur, L. (n.d.). Concrete Block . Retrieved from How Products are made : http://www.madehow.com/Volume-3/Concrete-Block.html

Our Block Manufacturing Process. (2019). Retrieved from Century Concrete Products : http://www.centuryconcrete.ca/pages/How_Blocks_Are_Made willia, r. (n.d.). Concrete blocks product and technical guide . Retrieved from thomas armstrong (concrete block) ltd : https://www.ribaproductselector.com/Docs/6/00486/external/COL387799.pdf

Hollow Core Slab Production . (n.d.). Retrieved from International prestressed hollowcore association: https://hollowcore.org/hollowcore/production/ Wells hollowcore. (n.d.). Retrieved from WELLS PRECAST : http://www.wellsconcrete.com/wp-content/uploads/2017/03/Ultra-Span-CS-Brochure-Booklet.pdf

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