BuildingTechnology1 - IBS

BUILDING TECHNOLOGY I (BLD 61403)

INDUSTRIALISED BUILDING SYSTEM (IBS)

PRECAST SYSTEM

TUTOR : AR EDWIN CHAN YEAN LIONG P R E PA R E D B Y : C H E E J I A X I N 0 3 2 7 3 9 2 CHEW RUI BO 0322334 CHIN MAN CHOONG 0324509 E R I C L O YA N N S H I N 0 3 2 4 9 2 2 LOONG BO LIN 0321469

TA B L E O F C O N T E N T 1. INTRODUCTION 1.1 1.2 1.3 1.4 1.5 1.6 1.7

Aim an d o b je ct ive Historica l b a ckg ro u n d o f ind u s t r i a l i z e d b u i l d i n g s y s t e m ( I B S ) Types o f in d u st ria lize d b u il d i n g s y s t e m ( I B S ) Advan t a g e s o f in d u st ria lize d b u i l d i n g s y s t e m ( I B S ) Disadva n t a g e s o f in d u st ria l i z e d b u i l d i n g s y s t e m ( I B S ) Case st u d y The Ap a rt m e n t

4. SCHEDULE OF IBS COMPONENT 4.1 4.2 4.3 4.4 4.5 4.6

Foundati on Col umns Beams Sl abs Wal l s Stai r cases

2 . T E C H N I C A L D R AW I N G S 2.1 Floor P la n / / / / /

foun d a t io n p la n grou n d f lo o r p la n first f lo o r p la n seco n d f lo o r p la n roof p la n

2.2 Elevat io n / / / /

south e le va t io n nort h e le va t io n east e le va t io n west e le va t io n

2.3 Structu ra l P la n / / / / /

grou n d f lo o r b e a m la yo u t first f lo o r b e a m la yo u t seco n d f lo o r b e a m la yo u t roof b e a m la yo u t roof st ru ct u re la yo u t

2.4 Sectio n 2.5 Axonom e t ric D ia g ra m

3. SEQUENCE OF CONSTRUCTION 3.1 Constru ct io n p ro ce ss o n -sit e 3.2 Constru ct io n p ro ce ss o f m od e l

5 . I B S C O M P O N E N T D E TA I L I N G 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8

Cast In- si tu Foundati on Pr ecast Col umns Pr ecast Beams Pr ecast Sl abs Pr ecast Wal l s Pr ecast Stai r cases Pr ecast Toi l et Pod Pr efabr i cated Roof Tr uss & Pur l i ns

6 . I B S S C O R I N G C A L C U L AT I O N 6.1 IBS Scor i ng Cal cul ati on 6.2 IBS Scor i ng Tabl e

7. CONCLUSION 8. REFERENCES

1

INTRODUCTION

1.1 AIM AND OBJECTIVE

AIM Through this project, we will be exposed to different types and methods of the IBS system and the calculation of IBS scoring. We are required to design a 3-storey apartment block using mainly Pre-cast system components. A physical sectional model of the building will be produced to show the IBS components in details.

OBJECTIVE / Develop our better understanding in different types of IBS construction method. / Build up our capability in applying appropriate IBS construction method in the production of a model for an apartment building. / Able to demonstarte a comprehensive understanding of IBS construction process through model making.

1.2 HISTORICAL BACKGROUND OF INDUSTRIAL BUILDING SYSTEM

In as early as 1624, the IBS concept was introduced when the wood panel houses were brought from England to North America. The IBS concept where blocks are divided into smaller and more manageable sizes for easy transportation were adopted during the construction of pyramids at Egypt.

In 1851, the Crystal Palace in United Kingdom was built using IBS method and this become a turning point of IBS construction. Frame components used were glass, wood and steel windows. The construction of Crystal Palace took only nine months to complete. This project actually proved that the potential of the IBS in the construction industry.

Crystal Palace

In 1963, few architects from Public Works Department (PWD) are sent by Malaysia Government to several European countries to study new construction technique in different countries since the government are focusing on housing development project in order to improve the quality of life at that time.

Following the success of their visits, the concept of IBS construction method was adopted in numerous mega-projects such as Petronas Twin Towers, Bukit Jalil Sports Complex and the Malaysian Light Rail Transit.

In today, the use of the IBS in construction is getting better and better. As reported, there are at least 21 different manufacturers and suppliers that are promoting their components in Malaysia. An IBS Centre has also been established in Jalan Chan Sow Lin, Cheras, Kuala Lumpur. They are the authorities who responsible for implementing strategies and introducing breakthroughs in the IBS technology to improve its performance and quality in the construction industry.

Petronas Twin Towers

1.3 TYPES OF INDUSTRIALIZED BUILDING SYSTEM (IBS) In Malaysia, according to the Construction Industry Development Berhad (CIBD), IBS defined as a technique of construction whereby building components are manufactured at factories or off site. To the accepted as a part of IBS, it needs to possess six characteristics below, which all of them are equally important to corroborate the achievement of the claimed benefits.

The six characteristics of IBS including: 1.

2.

3.

4.

5.

6.

Industrial production of components through pre-fabrication Highly mechanised in-situ processes i.e. slip-forms, post-tensioning, tunnel shutters Reduced labor during prefabrication of components and site works Modern design and manufacturing methods i.e. involvement of Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM) Systematic Quality Control i.e. ISO 9000 principles Open Building Concept i.e. permitting hybrid applications, adaptable to standardization and Modular Coordination (MC),

TYPES OF IBS To ensure the industrialised building system more systematic and mechanized in Malaysia, the IBS classified into 6 main types by CIDB. These 6 main IBS groups known as bring popularly used in Malaysia.

The six main IBS group including: 1. Pre-cast concrete framing, panel and box system.

The pre-cast concrete elements are concrete products that are manufactured and cured in a plant environment and then transported to a job site for installation.

This IBS consists of precast concrete columns,beams, slabs, walls, 3D components (i.e. balconies, staircases, toilets, lift chambers, refuse chambers), lightweight precast concrete and permanent concrete formworks.

2. Steel formwork system The steel formwork is prefabricated in the factory and then installed on site.This IBS is made up of tunnel forms, beams and columns mouldings forms, and permanent steel formworks.

This system is the least pre-fabricated amount in IBS, as it normally involves site casting.

Therefore, it is subject to structural quality control, high-quality finishes and fast construction with less site labor and material requirement. .

TYPES OF IBS 3. Steel framing system This IBS is commonly used with precast concrete slabs, steel columns/beams and steel framing systems and ies used extensively in the fast-track construction of skyscrapers. Apart from that, it is extensively used for light steel trusses consisting of cost-effective profiles cold formed channels and steel portal frame systems as alternatives to the heavier traditional hot-rolled sections.

4. Timber framing system Timber framing system included timber building frames and timber roof trusses.

Although the latter is more common, timber building frame systems also offer interesting designs from simple dwelling units to buildings such as chalets for resorts.

5. Blockwork system The elements of block work system consist of interlocking concrete masonry units (CMU) and lightweight concrete blocks. This system is widely used for non-structural wall as an alternative to conventional brick and plaster.

TYPES OF IBS 6. Innovative system This IBS combine multiple category of IBS, such as prefab with precast, blockworks with prefab, precast with brickwork to achieve better design, cost saving, energy efficiency and building friendliness to specific requirements by owners are very common nowadays in Malaysia too. Some of the new materials introduces in IBS include gypsum, wood wool, wepolymer, fiberglass and aluminum-based IBS components.

1 . 4 A D VA N TA G E S O F I N D U S T R I A L I S E D B U I L D I N G S Y S T E M It is important for Malaysia construction industry to evolve and be ready for globalization era whereby increase of productivity, quality and safety are compulsory and the reduction of cost and construction period must be considered. According to CIDB (2003), compares to the conventional construction method, IBS has the following advantages: 1. Increase site safety and neatness Adoption of IBS element result in less construction process especially wet work at the site.

Thus, a more organized and safer work platform are provided due to reduction of construction waste, site workers and prefabricated construction materials.

2. Cost saving IBS are manufactured at the factory, thus usage of machineries on site can be cut off. Besides, reducing on-site workers significantly reducing labor cost for contractors. Cost of transferring waste material can be minimizing due to quality control and reducing waste material.

3. Higher quality and better finishes As most components are manufactured in the factory, the quality of the components can be consistent and maintained as the working environment in the factory is easier to control.

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

4. Construction operation less affected by weather The project can be complete in shorter period due to rapid all-weather construction. The weather is less likely to affect the construction operation because the fabrication of IBS components is done in factory while at site is only erection of the components.

1 . 4 A D VA N TA G E S O F I N D U S T R I A L I S E D B U I L D I N G S Y S T E M 5. Less construction time Faster completion of projects due to advance off-site preparations and simplified installation process. Off-site production can start while the construction site is under earthworks. This offers earlier occupation of building.

6. Environmentally friendly The use of IBS will decrease construction waste on site such as concrete and formwork. Minimizing the use of formworks and props at site because of casting in factory.

1 . 5 D I S A D VA N TA G E S O F I N D U S T R I A L I S E D B U I L D I N G S Y S T E M Although there are many benefits in IBS, there are few weaknesses that can be discover in the implementation of IBS. IBS has the following disadvantages: 1. High Initial capital cost The IBS construction requires a high initial investment capital for the purchase of machineries, steel mould, foreign technology, transportation and wages of skilled workers for the installation process. The extra cost also involves in the training of foreign unskilled and semi-skilled laborer to enable them to involve in the IBS construction process.

2. Monopolise the market The IBS will enable the contractors and manufactures that implement this technology to monopolise the market.

This is because many companies are still reluctant to change due to the high investment cost. Then the small and medium industries that are reluctant to change will be affected and this will result in an unhealthy competition among them.

3. Site accessibility The site condition will affect the use of IBS. Since the IBS components are transported to the site and involves heavy machineries for the installation process. The site must have fair road surface and temporary site access for heavy vehicle and therefore, the road condition have to be improved before the construction proceed.

4. Transportation The transport used to carry IBS components need to be redesigning to be able to carry larger panels.

Lorries that are redesigned must meet the suitability and at the same time to follow the road regulations.

Currently, the transporters can carry limited weight, length and depth of IBS components stated in the road regulations therefore the optimum carrying capacity is not met.

1.6 CASE STUDY

SEKOLAH KEBANGSAAN BRICKFIELDS 1

SEKOLAH KEBANGSAAN BRICKFIELDS 1 FUNCTION OF BUILDING LOCATION YEAR COOPERATION OWNER IBS SYSTEM

// // // // //

Education Kuala Lumpur 2003 Ministry of Education Precast Concrete

Sekolah Kebangsaan Brickfields (1) is an national school located at Jalan Sultan Abdul Samad, Brickfields, Kuala Lumpur, where it has been placed for education for young Malaysians for 50 years. Initially completed in 1954, the school was completely demolished in February 2003, to make way for newer four-storey school building in its place. The compact design houses two houses in a total site area of 4,488m². The project has 75% of its building components prefabricated, such as columns, beam, staircases, and hollow core floor slabs. Due to its repetitive elements and rapid construction of precast components, the construction period lasted about 7½ months, with its completion date by 17th of September 2003.

1 . 7 T H E A PA R T M E N T

Three-storey building apartment with precast IBS system.

2

TTEECCHHNNIICCAALL WIINNGGSS DDRRAAW

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

3300

4400

2700

4400

3300

2700

A BALCONY

BEDROOM 1

BEDROOM 1

1800

B

9900

4600

MASTER BED ROOM

BALCONY

LIVING ROOM

MASTER BATH

BATH

BEDROOM 2

LIVING ROOM

DINING

DINING

BATH

BATH

D E

800

2700

C

BEDROOM 2

MASTER BEDROOM

YARD AC / DC LEDGE

KITCHEN

FOYER

FOYER

KITCHEN

YARD AC / DC LEDGE

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

3300

4400

2700

4400

3300

2700

A BALCONY

BEDROOM 1

BEDROOM 1

1800

B

9900

4600

MASTER BED ROOM

BALCONY

LIVING ROOM

MASTER BATH

BATH

BEDROOM 2

LIVING ROOM

DINING

DINING

BATH

BATH

D E

800

2700

C

BEDROOM 2

MASTER BEDROOM

YARD AC / DC LEDGE

KITCHEN

FOYER

FOYER

KITCHEN

YARD AC / DC LEDGE

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

3300

4400

2700

4400

3300

2700

A BALCONY

BEDROOM 1

BEDROOM 1

1800

B

9900

4600

MASTER BED ROOM

BALCONY

LIVING ROOM

MASTER BATH

BATH

BEDROOM 2

LIVING ROOM

DINING

DINING

BATH

BATH

D E

800

2700

C

BEDROOM 2

MASTER BEDROOM

YARD AC / DC LEDGE

KITCHEN

FOYER

FOYER

KITCHEN

YARD AC / DC LEDGE

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

1800

B

9900

4600

A

D E

800

2700

C

3300

4400

2700

4400

3300

2700

2

1

3

4

5

6

7

9

8

10

11

12

23500

3350

3350

3350

2700

3300

4400

2700

4400

3300

2700

2

1

3

4

5

6

7

9

8

10

11

12

23500

3350

3350

3350

2700

3300

4400

2700

4400

3300

2700

A

B

C

E

D

9900

3350

3350

3350

4600

1800

2700

800

E

C

D

A

B 9900

3350

3350

3350

800

2700

1800

4600

A

B

C

E

D

9900

3350

3350

3350

4600

1800

2700

800

2

1

3

4

5

6

7

9

8

10

11

12

23500

3350

3350

3350

2700

3300

4400

2700

4400

3300

2700

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

1800

B

9900

4600

A

D E

800

2700

C

3300

4400

2700

4400

3300

2700

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

1800

B

9900

4600

A

D E

800

2700

C

3300

4400

2700

4400

3300

2700

1

2

3

4

5

6

7

9

8

10

11

12

23500 2700

1800

B

9900

4600

A

D E

800

2700

C

3300

4400

2700

4400

3300

2700

3

SEQUENCE OF CONSTRUCTION

3.1 SEQUENCE OF CONSTRUCTION ON SITE 1. Excavation A process to remove earth, rock or other materials with tools, equipment or explosives.

It includes earthwork, trenching, wall shafts, tunneling and underground.

The entire excavation process includes: Setting out corner benchmarks Surveying ground and top levels Excavation to the approved depth Dressing the loose soil Making up to cut off level The construction of dewatering wells and interconnecting trenches Making boundaries of the buildings The construction of protection bunds and drains

2. The installation of foundations ground beams Precast concrete pad footings are laid on the excavation site while ground abeams and slabs are attached.

3.1 SEQUENCE OF CONSTRUCTION ON SITE 3. Erection of precast columns Precast concrete columns are bolted on the footings and the joint connection is casted with concrete. The columns are attached vertically and the rebar in the center reinforces the connections. They are joined by bolts and the bolts are grouted.

4. The installation of precast beams The beam is placed on the bearing pads of the column corbel and is secured a with a protruding rebar. The gaps in between are then grouted.

5. The installation of hollow core slab The slabs are fitted at the edges of the beam and the slab rebars secure the adjacent slabs. The gaps then grouted.

3.1 SEQUENCE OF CONSTRUCTION ON SITE 6. Erection of precast wall panels exteriors & interiors Wall panels are slotted in their designated positions between the skeletal structure.

The gaps are filled with grout to secure the wall.

7. The installation of precast staircases The landing and stairs are joined by concrete rebate and the gaps are grouted.

8. The installation of precast toilet pods Bathroom pods are used for the apartment. Thus, they are slotted to their designated locations.

3.1 SEQUENCE OF CONSTRUCTION ON SITE 9. Installation of prefabricated steel roof truss The prefabricated roof trusses are secured into the building via L-brackets and the ratters are bolted on the trusses.

3.2 SEQUENCE OF CONSTRUCTION OF MODEL

4

SCHEDULE O O FF IIBBSS C O M P O N E N TT

COMPONENT

FOUNDATION PAD FOUNDATION

STAIRCASE FOUNDATION

ISOMETRIC VIEW

300MM

1350MM

150MM

300MM

1150MM

400MM

850MM

850MM

300MM

SIDE VIEW

300MM

1900MM

150MM

300MM

1150MM 150MM

400MM 300MM 1450MM 600MM

850MM 850MM

PLAN VIEW 300MM

300MM

QUANTITY SYSTEM

34

CAST IN-SITU

850MM

1850MM

850MM

1

COLUMN

COMPONENT

C1

C2

C3

C4 300MM

ISOMETRIC VIEW

300MM

300MM

1550MM

300MM

200MM

3350MM

3350MM

3350MM

2800MM

200MM 300MM

SIDE VIEW

200MM 300MM 200MM

300MM 200MM

200MM 300MM 200MM 200MM

200MM

200MM

3350MM

3350MM

200MM

2800MM

3350MM

PLAN VIEW

500MM

700MM 500MM

700MM 300MM 700MM

500MM

500MM

1350MM

QUANTITY SYSTEM

24

PRECAST SYSTEM

54

18

6

SLAB

COMPONENT

S1

ISOMETRIC VIEW

S3

S2

1200MM 1200MM

1200MM

150MM

2400MM 150MM

3000MM 4100MM 150MM

1200MM

SIDE VIEW 150MM

1200MM

1200MM 150MM

150MM

1200MM 1200MM

1200MM

4100MM

2400MM

3000MM

PLAN VIEW

QUANTITY SYSTEM

24

PRECAST SYSTEM

24

24

SLAB

COMPONENT

S4

S5

ISOMETRIC VIEW

S6

1150MM

1350MM

1200MM

150MM

4800MM 2400MM

150MM

4100MM

1150MM

150MM

1200MM

1350MM

SIDE VIEW

150MM 150MM

150MM 1200MM 1350MM 1150MM

2400MM 4800MM

4100MM

PLAN VIEW

QUANTITY SYSTEM

6

PRECAST SYSTEM

12

6

SLAB

COMPONENT

S7

S8

S9

ISOMETRIC VIEW 1800MM

2850MM

2750MM 150MM

150MM

2750MM 1500MM

2400MM

2450MM

150MM

150MM

150MM

2750MM

2850MM

SIDE VIEW

2450MM

2850MM

2750MM

1500MM

2750MM

2400MM

PLAN VIEW

QUANTITY SYSTEM

6

PRECAST SYSTEM

6

6

SLAB

COMPONENT

S10

S11

S12

ISOMETRIC VIEW

1500MM 1350MM

2750MM 150MM

150MM 150MM 1650MM

2550MM 2400MM

2750MM

1350MM

1500MM

SIDE VIEW 150MM

150MM

150MM

1350MM 1500MM 2750MM

1650MM

QUANTITY SYSTEM

2400MM

2550MM

PLAN VIEW

6

PRECAST SYSTEM

6

3

SLAB

COMPONENT

S13

S14

ISOMETRIC VIEW

2400MM 2550MM 150MM

150MM

1550MM

2750MM

2550MM

2400MM

SIDE VIEW 150MM

150MM

2400MM 2550MM

1550MM

2750MM

PLAN VIEW

QUANTITY SYSTEM

3

PRECAST SYSTEM

3

BEAM

COMPONENT

B1

B3

B2

ISOMETRIC VIEW

150MM

150MM

150MM

150MM

150MM

400MM 1200MM

400MM

400MM

1940MM

2400MM

300MM 150MM

300MM

600MM

150MM

SIDE VIEW

150MM

1200MM

150MM

150MM

150MM

1940MM

2400MM

150MM

150MM

150MM

400MM

400MM

400MM

150MM 300MM 150MM

300MM 300MM

2400MM

PLAN VIEW 1500MM

QUANTITY SYSTEM

2240MM

24

PRECAST SYSTEM

18

66

BEAM

COMPONENT

B4

B6

B5

ISOMETRIC VIEW

3200MM 3000MM

400MM

4100MM

400MM 300MM

400MM

300MM 300MM

SIDE VIEW

3200MM

4100MM

3000MM 400MM

400MM

400MM

300MM 300MM 300MM

4100MM 3200MM 3000MM

PLAN VIEW

QUANTITY SYSTEM

18

PRECAST SYSTEM

6

30

BEAM

COMPONENT

B7

B9

B8

ISOMETRIC VIEW

150MM

3000MM 150MM

400MM

3900MM 150MM

400MM

400MM

300MM 300MM

SIDE VIEW 3000MM

150MM

4300MM

300MM

150MM

150MM

150MM

3900MM

150MM 4300MM

400MM

150MM

400MM

300MM 150MM 300MM 150MM

300MM

3000MM

3900MM

PLAN VIEW 4300MM

QUANTITY SYSTEM

18

PRECAST SYSTEM

6

24

DOOR

COMPONENT

D1

D2

ISOMETRIC VIEW

2100MM

2100MM

1200MM

900MM

SIDE VIEW

2100MM

2100MM

QUANTITY SYSTEM

36

PRECAST SYSTEM

6

COMPONENT

WINDOW W1

W2

W3

W4

ISOMETRIC VIEW

1200MM 600MM

1800MM

1200MM

SIDE VIEW

1200MM 800MM

1800MM

600MM

600MM 1200MM

QUANTITY SYSTEM

6

PRECAST SYSTEM

1200MM

6

1800MM

6

12

WALL

COMPONENT

W1

W3

W2

ISOMETRIC VIEW

2800MM 2800MM

2800MM

SIDE VIEW 2600MM 2000MM 3900MM

2800MM

2800MM 2800MM

3000MM 2400MM

QUANTITY SYSTEM

6

PRECAST SYSTEM

6

4300MM

6

WALL

COMPONENT

W4

W6

W5

ISOMETRIC VIEW

2800MM

2800MM

2800MM

SIDE VIEW 1100MM 2000MM 3750MM

2800MM

2800MM 2800MM

1500MM 2400MM

QUANTITY SYSTEM

6

PRECAST SYSTEM

6

4000MM

6

WALL

COMPONENT

W10

W12

W11

ISOMETRIC VIEW

2800MM 2800MM 2800MM

SIDE VIEW 2600MM 1850MM

2000MM

3000MM

QUANTITY SYSTEM

4400MM

6

PRECAST SYSTEM

2800MM

2800MM

6

6

WALL

COMPONENT

W7

W9

W8

ISOMETRIC VIEW

2800MM

2800MM

2800MM

SIDE VIEW

5000mm

3000MM

2800MM

3900MM

4300MM 3150MM

QUANTITY SYSTEM

6

PRECAST SYSTEM

6

30

WALL

COMPONENT

W13

ISOMETRIC VIEW

2800MM

SIDE VIEW

2800MM

1500MM

QUANTITY SYSTEM

24

PRECAST SYSTEM

STAIRCASES

COMPONENT ISOMETRIC VIEW

QUANTITY SYSTEM

1

PRECAST SYSTEM

5

IBS COMPONENT D E TA I L I N G

5 . 1 C A S T I N - S I T U F O U N D AT I O N

CAST IN-SITU FOUNDATION SYSTEM

Precast Concrete Column

Precast Concrete Column

Cast in-situ pad foundation

CONSTRUCTION METHOD

Column shoes filles with cement grout to prevent corrosion of anchor bolts.

Column Shoes

Bolted column connection.

The anchor bolts transfer tension, compression and shear forces to the reinforced concrete footing.

xxx xxx Column Stump

Anchor bolts

300MM x 300MM Column Stump

xxx thick Ground Slab

20mm diameter anchor belt

Concrete Footing xxx x xxx Ground Beam

5.2 PRECAST COLUMN

PRECAST COLUMN Precast concrete reinforced with bar

CONNECTION DETAILS 1. Bolted mechanical connections in the separate precast components are used to join the column to column splices. Metal bearing plated and embedded anchor bolts are cast into the ends of the columns.

2. Once the columns are assembled properly and mechanically joined, the open corners are then filled with high strength cement grout to provide full bearing between the elements and to protect the metal components from fire and corrosion.

Metal Shim

Metal bearing plate and embedded anchor bolts are cast on the end of the columns

Once assembed, the anchor bolts from the pile cap are tightened with bearing plate fixed at the end of upper column section with nuts by hammering.

This is then welded to prevent the connection from rotating

The open corners are then filled with high strength cement grout

5.3 BEAM TO COLUMN CONNECTION

BEAM TO COLUMN CONNECTION DETAILS

Column bars

Column ties

1. Beams are set on bearing pads on the column corbels

Weld plate cast into beam

2. Steel angles are welded to the metal plates cast into the beams and columns and the joint is grouted solid.

Weld plate cast into column Bearing pad on corbels

Welded plate Stirrup Prestressed tendon precast concrete column

Corbels

5.4 SLAB

SLAB TO BEAM CONNECTION

EDGE SUPPORT

Gap for screed / structural topping Precast hollow core slab

60 Average structural screed

SYSTEM Precast concrete slab ( Hollow core ) .

Reinforcement bars

Precast concrete beam

Roughen top & sides of beam Stirrups 30x3mm Neoprene bearing strip

INTERNAL SUPPORT Precast hollow core slab

Gap for screed / structural topping

60 Average structural screed Roughen top & sides of beam

Reinforcement bars

30x3mm Neoprene bearing strip Precast concrete beam

5.4 SLAB EDGE SUPPORT Precast hollow core slab

SLAB TO COLUMN CONNECTION SYSTEM Precast concrete slab ( Hollow core )

xxxmm thick loadbearing concrete wall 30x3mm Neoprene bearing strip

Horizontal reinforcement

.

Precast wall

Not less than 50mm bearing

Vertical reinforcement

INTERNAL SUPPORT Precast hollow core slab

Grout Reinforcement in accordance with project requirement

Horizontal reinforcement

Precast wall 30x3mm Neoprene bearing strip

No chamber on panel Not less than 50mm bearing

Vertical reinforcement

5 . 5 WA L L

WALL PANEL

Precast hollow core wall panel

CONNECTION DETAILS Precast panels are connected to each others or to floor and roof elements by using metal plates and angles, they are fastened by welding or bolting. Connections may be projected or recessed to provide flush finishing surface.

1.Bolted connection Bolted connections simplify and ‘speed-up the erection operation, because the connection is positive immediately. Final adjustment can be made later without tying up crane time. Bolting is in accordance with the erection drawings 2. Welded connection These connections are structurally efficient and adjust easily to varying field conditions. The connections are made by placing a loose plate between two structural steel plates that are embedded both in the castin-place or the precast concrete panel and welded together.

Bolts and nuts used to attach embedded plate cast on wall recession

20mm Urethane as a sealing material Loose field connector plated is bolted to embedded plate

Paper strips to ensure less filling in panel surfaces

Gap between wall panel are grouted with high strength cement

Recessed connection is grouted with high strength cement

Nail anchor with 1m spacing bolted into hole

High strength cement grouted

5 . 6 S TA I R C A S E 75mm thick concrete screed Bars from PC stairs

STAIRCASE SYSTEM

PC landing slab

Precast concrete staircase PC stairs risers

FABRICATION PRECAST STAIRCASE

Bars from RC stairs

Staircase flight, landings and steps are manufactured at the factory separately wherew ays of connection is being fabricated along with the stairs to be assembled directly on site.

Platform length are made with consoles for fitting of precast staircases. Additional cemen-sand mortar is used to secure staircase in place PC landing slab

Steel angle support bolted to RC wall

150mm Slab for staircase landing Precast staircase

PC stair raiser 150mm Slab for floor level Holes from PC stairs

Ground floor slab

Dowels drilled onto foundation

Precast concrete column

5.7 PRECAST TOILET POD

TOILET POD SYSTEM Proposed IBS system Bathrooms built in a factory setting offer fewer defects. This offsite construction method allow the bathroom pod manufacturer the ability to research and implement aesthetic and functional innovations to better improve the quality of the bathroom pod.

ADVANTANGES 1. Using bathroom pods lower construction costs by reducing construction time, providing quality and eliminating the bathroom defects lists.

2. Quality of work can be ensure and improved quality result in less snagging and better performance in use.

3. More significantly reduced construction times mean ealier income streams from the project.

source: http://www.modular.org/images/Bathroom%20Pods%20Whitepaper%20Dec16.pdf

5 . 8 P R E F A B R I C AT E D R O O F T R U S S & P U R L I N S

ROOF TRUSS SYSTEM

Welded steel plate Prefabricated steel roof truss Connector

Prefabricated gable steel roof truss Anchor bolts

Offer a high-strength, lightweight roof system that can be installed quickly. Prefabricated steel trusses last longer than conventional wood trusses and require little maintenance.

ROOF TRUSS TO BEAM CONNECTION

precast concrete roof beam

1. Prefabricated roof trusses are secured onto the building through anchor bolts and welded metal plates connection.

2. The steel trusses are prefabricated in the steel costing yard.

3. Trusses are lifted by a crane and is aligned into position and which is then bolted into place.

4. The C-channel purlins are then welded onto the rafters.

Prefabricated steel roof truss

Anchor bolt joint to precast concrete beam

precast concrete roof beam

Upper grid metal louver wall plates

6

I B S S C O R I NG G C A L C U L AT I O O NN

IBS SCORE CALCULATION CONSTRUCTION AREA i. Construction area ground floor ii. Construction area 1st floor iii. Construction area 2nd floor iv. Roof Area Total construction area

= = = = =

STRUCTURAL SYSTEMS i. Beams ii. Columns iii. Floor Slab iv. Roof truss

: : : :

Precast concrete beams Precast concrete columns Precast hollow core floor slabs Prefabricated steel roof truss

WALL SYSTEM i. Internal wall ii. External wall

: :

Precast concrete panel wall Precast concrete panel wall

: : : : : : : : :

62.5% complies to MS 1064 Part 10: 2001 100% complies to MS 1064 Part 10: 2001 77% complies to MS 1064 Part 10: 2001 40% complies to MS 1064 Part 10: 2001 83% complies to MS 1064 Part 4: 2001 100% complies to MS 1064 Part 5: 2001 100% 100% 100%

226m2 226m2 226m2 226m2 904m2

OTHER SIMPLIFIED CONSTRUCTION SOLUTIONS i.

Beams Columns Walls Slabs Doors Windows ii. Repetition of floor to floor height Vertical repetition of structural floor layout Horizontal repetition of structural floor layout

6 . 2 I B S S C O R I N G TA B L E

7

CONCLUSION

CONCLUSION

In this project, we were able to identify and collected relevant research data relating to Industrialised building system (IBS) construction. For project 1, we were required to do a thorough report on the construction process using IBS and develops our knowledge in the different varieties of IBS available in the current market. A set of architectural and documentation of an apartment is clearly explained in the report where IBS is used. By constructing an apartment, with most of its materials prefabricated, we demonstrated our comprehensive understanding on IBS through model making that includes the related basic structural elements and structural documentation. It also enable us to access and understand the method of calculating IBS score.

Through this module, we have understand and incorporate Industrialized building systems in our building where we learn that IBS requires less construction time because casting of precast element at factory and foundation work at site can occur simultaneously and the work at site is only the erection of IBS components. This leads to earlier completion of the building. Less labour on site due to precast component done off site will reduce the construction process on site and consequently reduce the number of labour required at site dramatically. We were able to fully optimised the use of material due to the utilisation of machine during the production of IBS components and ultimately lead to a higher degree of precision and accuracy in the production and consequently reduce material wastage thus offer a much higher quality and better finishes. Other than that, the formwork of IBS components are made of steel, aluminium or other materials that allows for repetitive use and this leads to considerable cost savings.

In conclusion, IBS construction is an efficient and cost effective construction system.

8

REFERENCES

8.1 REFERENCES

Mydin, M. A. O., Sani, N., &Taib, M. (2014). Industrialised Building System in Malaysia : A Review 2 Industrialised Building System History In Malaysia, 1002, 1–9.

Walker, J. (n.d.). The complete guide to crystal palaces - The Crystal Palace Foundation. Retrieved from http://www.crystalpalacefoundation.org.uk/ history/the-complete-guide-to-crystal-palacest MALAYSIA EQUITY Practical solution to rising costs. (2014), 2013(February), 1–24.

Industrialized Building System | IBS Malaysia | Aathaworld Sdn Bhd. (n.d.). Retrieved from https://www.aathaworld.com/industrialized-building-system-ibs The Definition Of Industrialised Building System Construction Essay. (2016, December 5). Retrieved from https://www.ukessays.com/essays/construction/ the-definition-of-industrialised-building-system-construction-essay.php Muro de hormigón armado / con paneles modulares / prefabricado by Alpha Béton | ArchiExpo. (n.d.). Retrieved from http://www.archiexpo.es/prod/ alpha-beton/product-59640-143498.html Steel Frame Structures | Steel Framing | Steel Structures. (n.d.). Retrieved from http://www.understandconstruction.com/steel-frame-structures.html Timber Frame Homes Prices | Timber Frame Cost | Hamill Creek. (n.d.). Retrieved from https://www.hamillcreek.com/process/timber-frame-cost/ airaland Forum. (n.d.). Retrieved from https://www.nairaland.com/1790503/decking-block-flats-port-harcourt/5 Inovatec System - An Innovative System Construction. (2014, July 01). Retrieved from https://www.youtube.com/watch?v=szhDT3n23ec Light weight steel roof trusses | janesroofs. (2018, May 24). Retrieved from https://janesroofs.co.za/portfolio-posts/light-weight-steel-roof-trusses/ CIBD, IBS Strategic Plan 1999-2003, Construction Industry Development Board (CIBD), Kuala Lumpur, 1999. pp: 4-6 IBS Survey. Construction Industry Development Board Malaysia (CIBD), Kuala Lumpur, 2003 K.S. Elliot. Mixed Options for Precast Concrete Construction, Building Design and Construction, 2003.

8.1 REFERENCES

Nazli, M. (2011, March 28). EnGiNeeR ThiNKinG.. Retrieved from http://inginiur.blogspot.com/2011/03/advantages-of-industrialised-building.html Lumpur, K. (2003). THE ESSENTIAL CHARACTERISTICS OF INDUSTRIALISED BUILDING SYSTEM, (1999), 10–11.

Disadvantages of IBS. (n.d.). Retrieved from https://www.scribd.com/doc/74996607/Disadvantages-of-IBS Excavation Construction. (2018, September 10). Retrieved from https://wollamconstruction.com/excavation-construction/ Register, I. C. (n.d.). EGC Companies, Inc. | ProView. Retrieved from http://www.thebluebook.com/iProView/1275366/egc-companies-inc/subcontractors/gallery/ 618404_our-services/901164_site-development-excavation-underground-utilities-contractor.html Pre-fab concrete installation. (n.d.). Retrieved from https://www.vroom.nl/en/serviceitems/14-pre-fab-concrete-installation (n.d.). Retrieved from http://www.spcind.com/usr/productdb5d.html?id=18z CONSTRUCTION PROCESS ON-SITE Light weight steel roof trusses | janesroofs. (2018, May 24). Retrieved from https://janesroofs.co.za/portfolio-posts/light-weight-steel-roof-trusses/