Advanced Architectural Construction Project 1: Industrialised Building System

ADVANCED ARCHITECTURAL CONSTRUCTION ARC60104 PROJECT 1 : INDUSTRIALISED BUILDING SYSTEM

TUTOR : MOHAMED RIZAL MOHAMED GRIFFIN KONG ZHEN ONN JACKSON GOH DING YUAN CHONG HOU YIN WONG YEW FAY LOW MENG ZHE

0336068 0332139 0336812 0335977 0331011

CONTENTS 1. INTRODUCTION TO IBS

1

2. INTRODUCTION TO APARTMENT

2

3. DRAWINGS

3 - 14

GROUND FLOOR PLAN FIRST FLOOR PLAN SECOND FLOOR PLAN TRUSSES & RAFTERS PLAN ROOF PLAN STRUCTURE PLAN LOWER GROUND FOUNDATION PLAN SECTIONS ELEVATIONS ISOMETRIC VIEW

4. PROPOSED SYSTEM & COMPONENTS

15 - 18

5. FABRICATION PROCESS

19 - 20

6. CONSTRUCTION METHOD

21 - 23

7. JOINT DETAILING

24 - 25

8. SCHEDULE

26 - 32

9. IBS SCORE

33

10. PRECEDENT STUDIES

34

11. CONCLUSION

35

12. REFERENCES

36

1. INTRODUCTION TO IBS

INTRODUCTION Industrialisation process is an investment in equipment, facilities and technology with the objective of maximising production output, minimising labour resource and improving quality while a building system is defined as a set of interconnected elements that join together to enable the designated performance of a building. The industrialised building system (IBS) can be defined in which all buildings such as wall, slab, beam, column and staircase are mass produced either in factory or at site factory under strict quality control and minimal wet site activities. IBS is a continuum beginning from utilizing craftsmen for every aspect of construction to a system that makes use of manufacturing production in order to minimise resource wastage and enhance value for end users.

The software elements include system design which study the requirements of the end user, market analysis, development of standardised components, establishment of manufacturing and assembly layout and process, allocation of resources and materials and definition of a building designer framework. The software elements provide a prerequisite to create the conducive environment for the industrialized building system (IBS) to expand.

The hardware elements are categorised into three major groups which include frame and beam system, panel system and box system. The framed structures are defined as those that carry loads through their beams and girders to column and to the ground whilst in panel system load are distributed through large floor and wall panels. The box system includes those systems that employ three dimensional modules (or boxes) for fabrication of habitable units that are capable of withstanding load from various directions due to their internal stability.

CLASSIFICATION OF IBS

IBS SCORING SYSTEM

The building system can be classified into a few types which depend on the particular interest of their users and producers. Four major groups can be distinguished such as systems using timber, steel and cast in situ concrete and precast concrete as their main structural and space enclosing materials. These systems can be further classified according to geometrical configurations of their main framing components that are the linear or skeleton (beams and columns) system, planar or panel system and three dimensional or box systems. From the structural classification, there are FIVE IBS main groups that are used in Malaysia as shown below:

PART 1 - Structural Systems (Max score 50pts)

a) Precast Concrete Framing, Panel and Box Systems b) Steel Formwork Systems c) Steel Framing Systems d) Prefabricated Timber Framing System e) Block Work System.

Example: P.C. Concrete Beams & Columns, Steel, Prefabricated Timber.

PART 2 - Wall Systems (Max score 20pts) Example: P.C. Concrete Panel, Glass, Dry Partition, Block Work PART 3 - Other Simplified Construction Solutions (Max score 30pts) Example: Standard components based on MS 1064, and repetition of structural layout and other productivity enhancing solutions as volumetric modular units, BIM and modular gridlines.

1

2. INTRODUCTION TO APARTMENT A

B

PRODUCED BY AN AUTODESK STUDENT VERSION

D

C

E

F

13000 1500

1200

2300

H

G

I

J

K

13000

1800

6200

6200

BALCONY

1800

2300

1200

1500

BALCONY

1 BATHROOM 1

BATHROOM 1

3000

UP 100

UP 100

MASTER BEDROOM

2 DINING AREA

3-STOREYS APARTMENT 4 UNITS PER FLOOR

LIVING HALL

FOYER

UP 100

FOYER

UP 100

BEDROOM 3

3 BEDROOM 3 BEDROOM 2

BATHROOM 2

BATHROOM 2

3000

KITCHEN

KITCHEN

ENTRANCE

4 UNITS PER FLOOR

ENTRANCE

F

F UP 100

UP 100

4

STAIRCASE

UP

2700

CORRIDOR

STAIRCASE

PRECAST CONCRETE INTERIOR WALL

UP

UP 100

5

UP 100

F

F ENTRANCE

ENTRANCE

KITCHEN

3000

MINUMUM 2 STAIRCASE FOR FIRE REGULATION

KITCHEN

BATHROOM 2

BATHROOM 2

BEDROOM 2

BEDROOM 2 BEDROOM 3

BEDROOM 3

UP 100

FOYER

6

UP 100

FOYER

7500 1500

DINING AREA

LIVING HALL

LIVING HALL

DINING AREA

7 MASTER BEDROOM

MASTER BEDROOM

UP 100

BATHROOM 1

3000

UP 100

BATHROOM 1

8 BALCONY

BALCONY

PRODUCED BY AN AUTODESK STUDENT VERSION

4 UNITS PER FLOOR

DINING AREA

BEDROOM 2

100SQM PER UNIT

PRECAST CONCRETE EXTERIOR WALL

LIVING HALL

7500 1500

PRODUCED BY AN AUTODESK STUDENT VERSION

MASTER BEDROOM

UNITS FLOOR PLAN SCALE 1:100

2

3. CONSTRUCTION DRAWINGS

PRODUCED BY AN AUTODESK STUDENT VERSION Y

A

B

D

C

E

F

13000 1500

1200

2300

H

G

I

J

K

13000

1800

6200

6200

BALCONY

1800

2300

1200

1500

BALCONY

1 W3

W2

W1

D4

W1

D4

W2

W3

W4

W4 D3

UP 100

LIVING HALL

DINING AREA

UP 100

DINING AREA

BATHROOM 1

BATHROOM 1

D2

D2

D2

D2

FOYER

UP 100

D2

FOYER

D2

UP 100

FFL 0.0+

3

FFL 0.0+

D3

D3

W5

W5 KITCHEN

D1

ENTRANCE

UP 100

BATHROOM 2

BEDROOM 3

BEDROOM 2

D1

ENTRANCE

UP 100

4

STAIRCASE

UP

UP

UP 100

ENTRANCE

BEDROOM 3

BATHROOM 2

5

UP 100

ENTRANCE

D1

KITCHEN

KITCHEN

BEDROOM 2

BEDROOM 3

BATHROOM 2

W5

3000

D1

BEDROOM 2

2700

CORRIDOR

STAIRCASE

3000

KITCHEN

BATHROOM 2

BEDROOM 3

BEDROOM 2

W5 D3

D3

UP 100

D2

FOYER

D2

6

UP 100

FOYER

D2

7500 1500

FFL 0.0+

D2

FFL 0.0+

D2

X'

PRODUCED BY AN AUTODESK STUDENT VERSION

2

X

7500 1500

D2

7 BATHROOM 1

DINING AREA

LIVING HALL

D3

DINING AREA

LIVING HALL

D3

UP 100

MASTER BEDROOM

W4

W3

3000

UP 100

MASTER BEDROOM

BATHROOM 1

W4

W2

D4

W1

D4

W1

W2

W3

8 BALCONY

BALCONY

Y

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

MASTER BEDROOM

D3

LIVING HALL

3000

MASTER BEDROOM

GROUND FLOOR PLAN

GROUND FLOOR PLAN SCALE 1:100

3

PRODUCED BY AN AUTODESK STUDENT VERSION Y

A

B

D

C

E

F

13000 1500

1200

2300

H

G

I

J

K

13000

1800

6200

6200

BALCONY

1800

2300

1200

1500

BALCONY

1 W3

W2

W1

D4

W1

D4

W2

W3

W4

W4 D3

UP 100

LIVING HALL

DINING AREA

UP 100

DINING AREA

BATHROOM 1

BATHROOM 1

D2

D2

PRODUCED BY AN AUTODESK STUDENT VERSION

2

X

X'

7500 1500

D2

D2

FOYER

UP 100

D2

FOYER

D2

UP 100

FFL 3.3+

3

FFL 3.3+

D3

D3

W5

W5 BATHROOM 2

BEDROOM 3

BEDROOM 2

KITCHEN

KITCHEN

D1

ENTRANCE

UP 100

BATHROOM 2

BEDROOM 3

BEDROOM 2

D1

ENTRANCE

UP 100

4

STAIRCASE

UP

UP

UP 100

ENTRANCE

BEDROOM 3

BATHROOM 2

5

UP 100

ENTRANCE

D1

KITCHEN

KITCHEN

BEDROOM 2

BEDROOM 3

BATHROOM 2

W5

3000

D1

BEDROOM 2

2700

CORRIDOR

STAIRCASE

3000

W5 D3

D3

UP 100

D2

FOYER

D2

6

UP 100

FOYER

D2

FFL 3.3+

D2

7500 1500

FFL 3.3+

D2

D2

7 BATHROOM 1

DINING AREA

LIVING HALL

D3

DINING AREA

LIVING HALL

D3

UP 100

MASTER BEDROOM

W4

W3

3000

UP 100

MASTER BEDROOM

BATHROOM 1

W4

W2

D4

W1

D4

W1

W2

W3

8 BALCONY

BALCONY

Y

1ST FLOOR PLAN

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

MASTER BEDROOM

D3

LIVING HALL

3000

MASTER BEDROOM

FIRST FLOOR PLAN SCALE 1:100

4

PRODUCED BY AN AUTODESK STUDENT VERSION Y

A

B

D

C

E

F

13000 1500

1200

2300

H

G

I

J

K

13000

1800

6200

6200

BALCONY

1800

2300

1200

1500

BALCONY

1 W3

W2

W1

D4

W1

D4

W2

W3

W4

W4 D3

UP 100

LIVING HALL

DINING AREA

UP 100

DINING AREA

BATHROOM 1

BATHROOM 1

D2

D2

PRODUCED BY AN AUTODESK STUDENT VERSION

2

X

X'

7500 1500

D2

D2

FOYER

UP 100

D2

FOYER

D2

UP 100

FFL 6.6+

3

FFL 6.6+

D3

D3

W5

W5 BATHROOM 2

BEDROOM 3

BEDROOM 2

KITCHEN

KITCHEN

D1

ENTRANCE

UP 100

BATHROOM 2

BEDROOM 3

BEDROOM 2

D1

ENTRANCE

UP 100

4

DOWN

DOWN

UP 100

ENTRANCE

BATHROOM 2

5

UP 100

ENTRANCE

D1

KITCHEN

KITCHEN

BEDROOM 2

BEDROOM 3

BATHROOM 2

W5

3000

D1

BEDROOM 3

STAIRCASE

2700

CORRIDOR

STAIRCASE

BEDROOM 2

3000

W5 D3

D3

UP 100

D2

FOYER

D2

6

UP 100

FOYER

D2

FFL 6.6+

D2

7500 1500

FFL 6.6+

D2

D2

7 BATHROOM 1

DINING AREA

LIVING HALL

D3

DINING AREA

LIVING HALL

D3

UP 100

MASTER BEDROOM

W4

W3

3000

UP 100

MASTER BEDROOM

BATHROOM 1

W4

W2

D4

W1

D4

W1

W2

W3

8 BALCONY

BALCONY

Y

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

MASTER BEDROOM

D3

LIVING HALL

3000

MASTER BEDROOM

2ND FLOOR PLAN

SECOND FLOOR PLAN SCALE 1:100

5

PRODUCED BY AN AUTODESK STUDENT VERSION A

B

D

C

E

F

13000 1500

1200

2300

1800

H

G

I

J

K

13000 6200

6200

1800

2300

1200

1500

1

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

3000

2 7500 1500

3

3000

4

2700

5

3000

6 7500 1500

7

3000

8

PRODUCED BY AN AUTODESK STUDENT VERSION

ROOF TRUSSES & RAFTERS PLAN SCALE 1:100

6

PRODUCED BY AN AUTODESK STUDENT VERSION A

B

D

C

E

F

13000 1500

1200

2300

1800

H

G

I

J

K

13000 6200

6200

1800

2300

1200

1500

1

3

3000

10°

4

2700

5

3000

10°

6

PRODUCED BY AN AUTODESK STUDENT VERSION

7500 1500 7500 1500

7

3000

8

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

3000

2

ROOF PLAN SCALE 1:100

7

PRODUCED BY AN AUTODESK STUDENT VERSION

A

B

D

C

E

F

13000 1500

1200

2300

6200

C1

6200

1800

C1

C1

C1(200x200)

I

J

K

13000

1800

FB1(200x300)

H

G

FB1

FB1

2300

C1

1500

C1

C1

FB1

FB1

FB1

1200

1

FB1

FB1

FB1

FB2

FB2 C2 (150x150)

FB2(150x300)

FB1

C2

C2

C2

FB2

C2 FB2

C2

C2

FB2

C1

C2

FB2

C1

C2

2

FB2 FB2

C2

FB2

FB2

C2

FB2

FB1

FB2

C1

C2

C2

C2

FB1

C2

C1

FB2

FB2

FB2

FB2

FB2

C1

C1

FB1

C1

FB2

FB2

FB1 FB1

FB1

FB1

FB2

3000

FB2

FB1

FB1 FB1

C1 FB1

FB1

FB1 C1

C1

C1

FB1

FB1

FB1

C1

UP

C1

FB1 C1

FB1 C1

FB1

FB2

FB1

C1

FB1 C1

FB2

FB2

FB1

FB1

C1

5

C1

FB1

FB2

C2 FB2

FB2

C2 C2

FB2

FB2

C2

C1

C2

FB2

FB2

C2

C2

C2

C2

FB2 C2

FB2

C2

C2

C1

FB2

FB2

FB2

C1 C1

FB1

FB2

FB1

FB1 C1

FB1

FB2

FB1

7

C1

C2

FB2

FB2

C1

FB2

FB2

FB1

FB2

3000

FB1

FB1

C2

6

C1 FB1

8 C1

FB1 C1

FB1

PRODUCED BY AN AUTODESK STUDENT VERSION

C2

C1 FB2 7500 1500

C1

FB1

C1

FB1

FB2

FB2

FB2 C2 FB1

UP

3000

FB1

C1

2700

STAIRCASE

FB1

4

C1

FB1

STAIRCASE

C1

3

FB2

FB1 FB1

PRODUCED BY AN AUTODESK STUDENT VERSION

FB2

C2 C1

7500 1500

PRODUCED BY AN AUTODESK STUDENT VERSION

C1

FB1

FB2

FB2

3000

FB1

STRUCTURE PLAN SCALE 1:100

8

PRODUCED BY AN AUTODESK STUDENT VERSION A

B

D

C

E

F

13000 1500

1200

2300

1800

H

G

I

J

K

13000 6200

6200

1800

2300

1200

1500

1

3000

2

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

7500 1500

3

3000

4

2700

5

3000

6 7500 1500

7

3000

8

PRODUCED BY AN AUTODESK STUDENT VERSION

LOWER GROUND FOUNDATION PLAN

LOWER GROUND FOUNDATION PLAN SCALE 1:100

9

PRODUCED BY AN AUTODESK STUDENT VERSION

A

B

D

C

E

F

13000 1200

2300

1800

I

J

K

13000 6200

6200

1800

2300

1200

1500

PRODUCED BY AN AUTODESK STUDENT VERSION

2200

ROOF 400

W3

D2

D4

D4

D2

W3

3300

2900

SECOND FLOOR 400

W3

D2

D4

D4

D2

W3

9900

3300

2900

FIRST FLOOR 400

D2

D4

D4

D2

W3

3300

GROUND FLOOR

1000 300

SECTION X - X' SCALE: 1:

PRODUCED BY AN AUTODESK STUDENT VERSION

W3

2900

PRODUCED BY AN AUTODESK STUDENT VERSION

1500

H

G

SECTION X - X’ SCALE 1:100

10

PRODUCED BY AN AUTODESK STUDENT VERSION

1

2

4

3

5

6

7500

7500

1500

3000

2700

3000

1500

3000

400 3300

2900 900

SECOND FLOOR

400 9900

3300

2900

FIRST FLOOR 400 3300

2900

GROUND FLOOR

PRODUCED BY AN AUTODESK STUDENT VERSION

ROOF

1000 300

SECTION Y - Y' SCALE: 1:

PRODUCED BY AN AUTODESK STUDENT VERSION

3000

8

7

SECTION Y - Y’ SCALE 1:100

11

PRODUCED BY AN AUTODESK STUDENT VERSION

A

B

D

C

E

F

13000 1200

2300

1800

I

J

K

13000 6200

6200

1800

2300

1200

1500

W2

W1

D4

D4

W1

W2

W3

W3

W2

W1

D4

D4

W1

W2

W3

W3

W2

W1

D4

D4

W1

W2

W3

3300 3300

PRODUCED BY AN AUTODESK STUDENT VERSION

W3

3300

ELEVATION A SCALE: 1:

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

1500

H

G

FRONT ELEVATION SCALE 1:100

12

PRODUCED BY AN AUTODESK STUDENT VERSION

1

2

3

5

4

6

7500 1500

7500 3000

2700

3000

1500

3000

W5

W5

W4

W4

W5

W5

W4

W4

W5

W5

W4

3300 3300

PRODUCED BY AN AUTODESK STUDENT VERSION

W4

3300

ELEVATION B SCALE: 1:

PRODUCED BY AN AUTODESK STUDENT VERSION

PRODUCED BY AN AUTODESK STUDENT VERSION

3000

8

7

SIDE ELEVATION SCALE 1:100

13

ISOMETRIC VIEW NOT TO SCALE

14

4. PROPOSED SYSTEMS & COMPONENTS PRECAST CONCRETE SYSTEM Precast concrete is a form of concrete that is prepared, cast and cured off-site, usually in a controlled factory environment, using reusable moulds. Precast concrete elements can be joined to other elements to form a complete structure. It is typically used for structural components such as; wall panels, beams, columns, floors, staircases, pipes, tunnels, and more. Structural steel frames can provide an alternative for prefabricated structural components, but precast concrete can be more economical and sometimes more practical. Many buildings now include a mixture of both construction techniques, sometimes incorporating structural steelwork, in-situ concrete and precast concrete elements.

ADVANTAGES OF PRECAST CONSTRUCTION

ADVANTAGES OF PRECAST CONSTRUCTION

Precasting is good at producing large numbers of identical components. For example, building an affordable housing project with identical apartments could use precasting to produce wall slabs and floor slabs for all the apartments, and then lift them into place and connect them.

Precasting is good at producing large numbers of identical components. For example, building an affordable housing project with identical apartments could use precasting to produce wall slabs and floor slabs for all the apartments, and then lift them into place and connect them.

As it is done in a purpose-built precasting yard or factory, it makes construction easier for the following reasons:

As it is done in a purpose-built precasting yard or factory, it makes construction easier for the following reasons:

- The construction is done on the ground rather than at height.

- The construction is done on the ground rather than at height.

- It can be done inside a climate-controlled structure, eliminating problems of rain, dust, cold, or heat.

- It can be done inside a climate-controlled structure, eliminating problems of rain, dust, cold, or heat.

- Specialised formwork (moulds) can be built for doing many repetitions of the same component.

- Specialised formwork (moulds) can be built for doing many repetitions of the same component.

- Specialised equipment can be used to make, move, and pour the liquid concrete.

- Specialised equipment can be used to make, move, and pour the liquid concrete.

- Curing takes place in a controlled environment.

- Curing takes place in a controlled environment.

This means that the quality of precast components can be very high. Since the components can be made beforehand, construction can be very quick. In cast-in-situ construction, engineers have to build each set of components after the previous set has finished, which does take time, as concrete generally takes 28 days to reach its full strength.

This means that the quality of precast components can be very high. Since the components can be made beforehand, construction can be very quick. In cast-in-situ construction, engineers have to build each set of components after the previous set has finished, which does take time, as concrete generally takes 28 days to reach its full strength.

15

PRECAST CONCRETE COLUMNS

PRECAST CONCRETE BEAMS

Precast concrete columns are one of the load bearing elements in the structural component of a building. To minimize the number of precast elements in construction, the columns have up to maximum 3 stories height. The columns provide multiple corbels to support floor or roof beams. Precast Concrete Columns can be circular, square or rectangular. It can be designed and manufactured to your specifications and can incorporate additional features and fittings. Precast Concrete Columns are considered for use on in-situ concrete flat slab projects where there’s a high demand on tower crane hook time and tight construction programmes.

Beams are horizontal components that support deck members like double tees, hollow-core, solid slabs, and sometimes other beams. They can be reinforced with either prestressing strand or conventional reinforcing bars. This will depend on the spans,loading conditions, and the precast producer’s preferred production methods.

TYPES OF PRECAST CONCRETE COLUMNS

TYPES OF PRECAST CONCRETE BEAMS

1. Edge columns

– symmetrical in one direction.

1. Internal beams – where floor loading is approximately symmetrical

2. Internal columns

– symmetrical in all directions.

2. External beams – where floor loading is predominantly non-symmetrical.

3. Corner columns

– not symmetrical at all.

PROPOSED COLUMN SYSTEM USED IN APARTMENT

3 KEY SHAPES

Single Storey Cobel Column

1. Rectangular 2. Inverted Tee Beam

Columns with Corbels are compression members casted monolithically with corbels to support floor beams. They are produced under controlled factory conditions with high strength concrete creating a superior quality durable product with no need for extra fireproofing.

3. L-Beam

Advantages of Using Corbel Column - They make the construction process much simpler and faster.

- They provide maximum flexibility in design, shape and application.

- They look clean, finished look of the structural components.

- They are more efficient than steel columns in high corrosive areas.

PROPOSED BEAMS USED IN APARTMENT RECTANGULAR BEAM A rectangular beams is typically good at resisting torsion and biaxial bending since its second moment of area is large in both axis.

16

PRECAST CONCRETE SLABS

PRECAST CONCRETE STAIRCASE Precast concrete stairs and landings are the ideal solution for fast track high quality concrete staircase construction.

The precast concrete staircases are bracings between different floors that strengthens the stability of the building structures. For the proposed building, staircase used is typical dog leg building at the opposite side of the building giving equal distribution of structural holds.

TYPES OF PRECAST CONCRETE SLABS Solid Flat Slab Flat slab is a reinforced concrete slab supported directly by concrete columns without the use of beams. Flat slab is one sided or two-sided support system with sheer load of the slab being concentrated on the supporting columns and a square slab.

Hollow Core Slab Is a prestressed precast concrete element incorporating continuous voids to reduce self-weight whilst providing an efficient structural section manufactured by slipform, extrusion or wetcast.

Double Tee Is a load-bearing structure that resembles two T-beams connected to each other side by side. In most cases, the lengths of the pretensioning beds are of about 200 to 500 feet long.

Single Tee Is a load-bearing structure that resembles only ONE T-beams connected to a slab. In most cases, they usually span ranging from 30 to 100 feet. While span length ranging from 3.5 to 30m.

3 OPTIONS ARE AVAILABLE FOR PRECAST STAIRCASE - A single precast unit containing all the flights and landings - Separate precast flights and landings - Parts of the flights and landings are made in one piece.

ADVANTAGES OF USING PRECAST STAIRCASE - Quality Assurance - Usage of Prestressed Concrete - The high-density Precast Concrete is more durable - Construction process reduces the time, increases the productivity

PROPOSED TYPE OF SLAB USED IN APARTMENT

PROPOSED TYPE OF STAIRCASE USED IN APARTMENT

Hollow Core Slab

U-Shaped Middle Landing Staircase

Reason: - Minimum site in-situ concrete - Long spans - Flexibility of design

Reason: - Easy placement of the staircase - Save space - Adapt to building design layout

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PREFABRICATED STEEL CASTING ROOF TRUSS SYSTEM

COMMON TYPES OF STEEL TRUSSES

ROOF OVER TRUSSES

ADVANTAGES OF USING STEEL TRUSSES - High strength-to-weight ratio - Steel is incredibly durable - Complete pest resistance - Fire-resistant

PROPOSED TYPE OF TRUSSES USED IN APARTMENT STEEL ROOF TRUSSES

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5. FABRICATION PROCESS TYPES OF FABRICATION PROCESS OF PRECAST CONCRETE COMPONENTS Normal Casting Fabrication Process

Dry Casting Fabrication Process

1. Assembly mould 2. Mould cleaning and preparation 3. Fixing of rebars/ cast in items/ prestressing strands 4. Final inspection before casting 5. Concreting 6. Curing 7. Demoulding 8. Final inspection/ transfer to storage yard

1. Base mould cleaning and preparation 2. Prestressing strand hauling and tensioning 3. Concreting 4. Curing 5. Detensioning of strands 6. Final inspection/ transfer to storage yard

1. Assembly Mould

3. Fixing of Rebars/ Cast in items/ Prestressing strands

The level of flatness of the assembly mould need to be checked before assembling the mould for panel casting. To also ensure that the dimensions are within the specified tolerances. Then the worker will also check for the squareness of the mould form. The reinforced cage is positioned in the partly assembled mould.

Rebars, cast in items, corrugated sleeves pipes, recessed, lifting hooks and insert must be correctly positioned and properly secured. Use of fabrication rig can help to ensure the accuracy of rebars fixing and spacing. Sufficient number of spacers with the correct sizes should be properly placed and secured.

2. Mould Cleaning and Preperation

4. Final Inspection Before Casting

The mould should be clean and free from debris and old mortars using removers or scalings bars. Forms oil or mould release agent should be applied evenly over the mould surface. Then the workers will check for the joints and edges of the mould, bolts, stoppers, tie rods, side props, and rubber seals are properly secure.

Check and verify all details comply with drawings and also the mould fitting conditions including blockout details. The workers will also check the base mould level again before casting, in particular for site precasting where the other concurrent site activities may have shifted the mould level.

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5. Concreting

7. Demoulding

Usually concrete grades used are checked if it is according to the design specifications. Conduct slumps test in compliance with 78 to assess the workability of the concrete mix before placing the concrete to the mould.SS Vibration and compaction should be carried out in more congestion areas. Form vibration can be used for slende and thin elements. Then spreading and levelling of concrete surface level after initial set. Power trowel or Float is recommended for smooth surface.

Minimum concrete strength required may be higher to overcome the suction and frictional forces during demoulding. Cube test should be conducted to verify the concrete strength of element before demoulding. Concrete strength for reinforce precast element are minimum 10N/mm2. Then loosen and remove all bolts and pins and end the side mould form before lifting.

6. Curing

8. Final Inspection/ Transfer to Storage Yard

Immediately after the concrete is poured, the curing process begins. This may include putting a tarp over the product overnight to capture the heat generated as part of the hydration process which speeds up curing. The controlled environment of a precast factory enables the product to properly cure and reach the full design strength much quicker than in the field.

Check the condition of the finished product and also verify the critical dimentions. All the markings shold be properly identified and placed on elements showing the location, member type, size, weight, and orientation as per shop drawing. Most importantly, check the elements and have achieved 75% of their design concrete strength before deliver to site for erection.

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6. CONSTRUCTION METHOD 7.1 IBS CONSTRUCTION STAGES MATERIALS SUPPLY

MATERIALS DELIVERY

CONSTRUCTION PROCESS

WALL INSTALLATION

FINISHING

FIXTURES INSTALLATION

M&E WORKS

7.2 CONSTRUCTION METHOD & SEQUENCE 7.2.1 LOWER GROUND

EXCAVATION OF THE SITE

AFTER COMPLETION OF FOOTING, THE EXCAVATION ARE THEN BACKFILLED

FOOTINGS ASSEMBLED ON SITE

PRECAST COLUMN ARE PLACED ON TOP OF EACH STUMPS

GROUND BEAM ARE THEN INSTALLED

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7.2.2 GROUND FLOOR

BEAMS FOR GROUND FLOOR LEVEL ARE RESTED ON THE COBEL. L-SHAPED METAL PLATES ARE THEN WELDED TO FIX IT’S PLACE.

WALL PANELS ARE THEN SLOTTED INTO PLACE INCLUDING EXTERIOR AND INTERIOR WALL.

STAIRCASE ARE THEN SLOTTED ON TOP AND BOTTOM OF THE LANDING.

7.2.3 FIRST FLOOR

7.2.4 SECOND FLOOR

THE HOLLOW CORE SLABS ARE INSTALLED AND SUPPORTED ON BEAMS.

THE HOLLOW CORE SLABS INSTALLATION ARE REPEATED AS SAME ASTHE FIRST FLOOR

THE STEPS ARE REPEATED WHERE COLUMN FROM GROUND FLOOR AND FIRST FLOOR ARE CONNECTED WITH METAL BEARING PLATES.

THE COLUMNS ARE CONNECTED USING THE SAME METHOD AS FOLLOWED

WALL AND STAIRCASE ARE ALSO CONSTRUCTED WITH THE SAME METHOD AS GROUND FLOOR.

WALL AND STAIRCASE ARE AS FOLLOWED

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7.2.5 ROOF

7.2.6 FINISHING

THE BASE OF THE ROOF ARE THEN PLACED ON TOP OF THE BEAMS TO SUPPORT THE ROOF TRUSSES

PREFABRICATED STEEL TRUSSES ARE PLACED INTO POSITION AND SECURED WITH BOLTS

DOORS, WINDOWS, HANDRIALS AND M&E WORKS ARE TO BE DONE

ROOF ARE THEN SCREWED ON TO THE PURLINS

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7. JOINT DETAILINGS COLUMN TO COLUMN JOINARY

COLUMN BEAM AND FLOOR SLAB JOINARY

Metal bearing plates and embedded anchor bolts are cast into both ends of the columns. After the columns are mechanically joint together, the connection are grouted to provide full bearing between elements and protected the metal components from fire and corrosion.

The hollow core slab panels are placed on top of the rectangular beam, and the beam is connecting the columns.reinforced bar ties are grouted into keys between slab elements.

SHINS THE ENTIRE JOINT IS DRY-PACKED WITH GROUT AFTER ALIGNMENT

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COLUMN AND FOUNDATION JOINARY

COLUMN AND FOUNDATION JOINARY

The column is connected to the foundation footings with bolts. Bolts and nuts are connected from 4 sides of the footing.

Making of Precast Concrete Staircase have 5 steps: 1. Craft template of landings 2. Mount pad in the design position, using a template 3. Trowel to put on the receiving space platforms cement- sand mortar 4. Install the 1st flight of the stairs 5. Lay and unhook the flight

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8. SCHEDULE

Ground, First, and Second Floors

FOUNDATION

Components

COLUMN

Components

C1

Isometric View

200

200

200

200

C6

C5

C7

200 200

300

150

150 150

200

150

150

System

200

200

Prefabricated

Quantity

200 200

32

44

200 200

200

32

Cast in situ

300

600

600

44

Plan view

200 200

200

Elevation View

System

C4

Isometric View

200

Quantity

C3

C2

24

12

84

12

72

12

12

Precast

26

Ground, First, and Second Floors

200mm 200 mm thickness

Ground, First, and Second Floors

EXTERIOR WALL

Components EW1

EW4

12

System

Precast

Ground, First & Second Floors

18

2100

12

400

Quantity

12

1600

2900

12

1300

EW9

EW8

2900

12

2500

EW7

2900

2900

System

12

2900

Quantity

1500

2900

Elevation View

2900

Elevation View

2900

Isometric View

4700

EW6

EW5

Isometric View

1300

EXTERIOR WALL

Components

EW3

EW2

200mm thickness

1000

2800

12

32

Precast

200mm thickness

EXTERIOR WALL

Components EW9

EW11

EW10

EW12

Isometric View

System

12

2900

Quantity

2900

2800

2900

2900

Elevation View

5000

2800

12

12

1600

12

Precast

27

Ground, First, and Second Floors

150mm thickness

Ground, First, and Second Floors

INTERIOR WALL

Components EW13

IW1

IW4

IW3

IW2

60

Quantity

12

1000

264

12

24

System

Precast

2900

24

1600

IW7

2900

12

2900

System

2900

2900

Quantity

2800

IW6

2900

Elevation View

IW5

2900

Elevation View

2900

Isometric View

1300

INTERIOR WALL

Components

Isometric View

6000

150 mm thickness

264

24

1600

12

Precast

150mm thickness

Ground, First, and Second Floors

INTERIOR WALL

Components IW8

IW10

IW9

IW11

Isometric View

System

24

1050

1600

12

12

2900

Quantity

2900

2100

2900

2900

Elevation View

2800

12

Precast

28

Ground Floor

First & Second Floors

SLAB

Components

SLAB

Components

Isometric View

Isometric View 1290

System

80

80

3500

Quantity

2700

Precast hollow core

4

4500

20

Plan View

1290

2900

40

3500

40

1000

1290

2700

System

4500

Quantity

1290

2900

Plan View

1290

1000

1290

36

8

Precast hollow core

29

Ground, First, and Second Floors ( included Footing)

BEAM

BEAM

Components B1

Components

B2

B3

B4

Isometric View

1300

2500

Precast

24

16

200

Quantity

16

200

32

6000 200

48

Plan view

4800

1600

200

System

2800

200

Quantity

B6

Isometric View

200

Plan view

B5

16

Precast

System

Ground, First, and Second Floors (Include Footing)

BEAM

Components B7

B8

B9

2825

1358

B10

Isometric View

16

150

System

80

150

Quantity

2150 150

2100 200

Plan view

16

32

Precast

30

Ground, First, and Second Floors (Include Footing)

Ground, First, and Second Floors (Include Footing)

Components

BEAM

Isometric View

6025

Precast

Quantity

System

1325

1050

150

32

32

Plan view

150

1650 150

System

Isometric View

150

Quantity

B14

B13

B12

B11

Plan view

BEAM

Components

32

16

Precast

31

Ground, First, and Second Floors

Ground, First, and Second Floors

WINDOW

Components W1

W3

W2

WINDOW

Components W4

W4

Isometric view

STAIRCASE W5

Isometric view 2900

1000

1208

2072

1778

2072

200

200

200

200

Plan view 625

2500

980 200

200

Plan view

815 UP

280

Quantity

12

12

System

12

12

Quantity

12

System

Prefabricated

12

4

Prefabricated

Ground, First, and Second Floors

DOOR

Components D1

D3

D2

ROOF TRUSS, PURLIN

Components D4

Isometric view

Isometric view

120

150

150

200

1200

750

900

Elevation view

1984

3400

124

Plan view

830

124 640

7700

Quantity

System

12

24

16

Prefabrication

16

Quantity

44

System

Prefabricated

38

32

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33

10. PRECEDENT STUDIES WOHNREGAL, BERLIN

SERI JATI APARTMENT , SHAH ALAM

Wohnregal is a project designed to house a variety of life/work units in Berlin. The 6 storeys structure was assembled within 6 weeks. The usage of precast concrete systems allowed for a shorter construction time and a cost saving construction which led to more affordable housing areas which was a problem for people in Berlin at that time. The precast concrete components used are such as TT slabs, precast columns and beams and prefab staircase.

The use of TT roof and slabs allows a wider selection of space configuration with less limitation due to the elimination of the usage of structural walls within which allows the spaces within the building to adapt to the ever changing urban lifestyle as the spaces can be configured in a number of ways. the choice of using precast concrete elements in the construction of wohnregal allows for interior spaces to be arranged in a wider selection of configurations, dismissing any preconceptions that serial construction produces standardized units. since the long-spanning TT roof and floor slabs offer a clear span that does not require any other structural walls, the architects have used a curtain wall consisting of large-scale standard sliding doors as the façade. besides reducing construction costs, the curtain wall offers tenants the choice to open up their spaces to the surroundings during the summer months, while it also highlights the presence of the precast concrete structure, both within the building and toward the outside.

Located in Shah Alam , Selangor , Seri Jati Apartment is a low cost apartment with 6 total blocks, 10 storeys for 3 of them and 11 storeys for the other 3 blocks , spanning over a land area of 18.75 acres. There are a total of 948 units to be offered with each unit consisting of 3 bedrooms and 2 bathrooms with 813sf built up.

The structural system is mainly precast concrete system such as precast column and precast beam with in situ concrete floor using reusable formwork. The components in the structure such as wall thickness and column size is highly compliant to MS 1064 with addition of a high repetition for both vertical and horizontal plain.

A total IBS score of 81.9 is achieved. A higher point could be achieved by reducing or eliminating the use of brick walls and an increase of the compliance of MS 1064 in modular coordination for some of the structural and architectural elements.

34

11. CONCLUSION

Through this project, we are able to design an apartment with 3 storeys height and also understand more about IBS score, construction method of IBS, and also the fabrication process as well. The process of this design needed to be implement with the MS1064 in oder to achieved the modularity system.

In this project we are using precast concrete system to build this apartment, during this research period, we have a clear understanding on the construction sequence and also all the joinary detail used only in precast concrete system.

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12. REFERENCES 1. Essays, UK. (November 2018). The Definition Of Industrialised Building System Construction Essay. Retrieved from https://www.ukessays.com/essays/construction/the-definition-of-industrialised-building-system-construction-essay.php?vref=1 2. Designing Buildings Wiki (April 2020). Precast concrete. Retrieved from https://www.designingbuildings.co.uk/wiki/Precast_concrete 3. Concrete Society (2019). Precast columns. Retrieved from http://www.concrete.org.uk/fingertips-nuggets.asp?cmd=display&id=307 4.

Precast/Prestressed Concrete Institute (2020).

Beams and Columns.

Retrieved from https://www.pci.org/PCI/Design_Resources/About_Precast/Beams_and_Columns.aspx?hkey=2e7626f2-22e6-401d-9f31-c6676b3d460f 5. The Construction Civil Engineering Home (2018). Pre-Cast Concrete Walls – Types, Connections, and Advantages. Retrieved from https://theconstructor.org/concrete/precast-concrete-walls-types-connections-advantages/37998/ 6. ACP Concrete LTD (2017). Precast Concrete Products. Retrieved from http://www.acp-concrete.co.uk/precast-concrete-products/floors-and-stairs/concrete-stairs/ 7. SlideShare (2017). Steel Trusses. Retrieved from https://www.slideshare.net/roopachikkalgi/steel-trusses 8. The Construction Civil Engineering Home (2018). Types of Precast Components in a Building. Retrieved from https://theconstructor.org/concrete/types-of-precast-components-in-a-building/6325/

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