CA

ABPL20033 - Construction Analysis, Semester 2 - 2019 Dr Alberto Pugnale, Subject coordinator Dr Sofia Colabella, Senior Tutor Anastasia Sklavakis, Tutor Natalie Ang, 996016, 14/9/19 Lake Wendouree House, Tutorial 6 ASSIGNMENT 2

FLIPBOOK SECTION 2D: construction stages, details and annotations

Melbourne School of Design, photo by Sofia Colabella

STAGE 1

PLAN

FOUNDATION SYSTEMS In this stage, the site is being prepared for the building construction. Prior to commencing construction, the site surveyors and architects have to acquire the necessary permits from relevant authorities. Once the permits have been obtained, excavators, bobcats and trucks are brought in. The ground is then excavated and the unwanted soil is placed in a truck, as it will not be reused in this project. Once this has been completed, the land surveyor will set out the site, preparing for the service layouts in the next stage.

After the excavations have been completed, any excess sand or soil from the site that will not be reused in the future will be removed. Smaller machinery, such as bobcats, will help in this process. The soil will be put into the back of a truck and be taken off site to be disposed of.

Utilising large machinery such as excavators to dig the trenches in preparation for the service to be laid.

Hoardings are set up around the site to prevent pedestrians from entering the site and maintaining public safety whilst the house is being built.

Site is set out according to the architectural drawings and key points and gridlines are established. This will help to guide the construction process and ensure the accuracy, especially in important stages such as laying out the services. This is done by the land surveyor.

In preparation for the demolition to occur on site, trees and other surface vegetations are removed unless the architect has specified that they be retained.

Workers on site must be wearing protective equipment such as helmets and high visibility clothing especially around large machinery.

Trucks are brought on to site to remove any unwanted soil once the site has been excavated.

Truck on site ready to dispose the surplus excavated soil offsite.

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STAGE 1

Site is levelled to make the base of the foundation level

SECTION

FOUNDATION SYSTEMS

Once excavations have been completed, the land surveyor measures and marks out the site using survey pegs.

Excavators clear the site

In stage one, the site is being prepared for the building construction.

Excavation and demolition occurs on site.

Key steps in this stage are : • In order to commence construction, all required permits are obtained from local authority • Hoardings are erected and the site is secured • Anything that needs to be retained such as materials and trees are protected • Demolition • Site office is established • Site set-out completed by land surveyor • Levels of the site are set out and the grid of the site is pegged out ,according to the architectural specifications, in preparation of the service layout.

• Footings are dug in preparation for the pouring of the blinding concrete • Site is levelled • Trenches, for footings and pipes, are dug to the requisite depth, as specified by the structural engineer in the engineering drawings

Due to the size of the project, a site office has been established. The site office provides a space for the workers to hold meetings and the site documentations are often stored here.

Machinery such as bobcats and excavators have been brought in to dig the trenches.

WORKS IN THIS STAGE IN ACCORDANCE WITH

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STAGE 2

PLAN

FOUNDATION SYSTEMS : SERVICES In stage two, the trenches have been dug and the services are ready to be installed. Services such as mains water, gas and electricity will be laid out in preparation of the next stage where the floor system will be installed.

Concrete pump on site to pour the blinding concrete once the new services have been laid and the compact fill has been brought in. This is done in preparation for the next stage - the foundation systems.

Compact fill has been brought onto site, preparing for the pouring of the blinding concrete.

Compact fill is important to provide a good foundation, preventing concrete cracking and sinking concerns.

BACKFILL

A

PIPE FOUNDATION

Prior to having the concrete poured, services are laid out. The plumber will lay the plumbing and connections to the local services line will be established.

Any existing services that are retained will be capped. The new service pipes will be laid out in the trenches. These are then backfilled to help protect the pipes.

BACKFILL

PIPE FOUNDATION

Pipes are capped to ensure that unwanted objects do not enter the pipes

A Waste pipe installation Floor waste pipe installation

Signage on the construction site indicated a water bore is in use.

A bore is used to drill into the ground to access underground quifers and pumping this water to the surface. Before using bore water, the water must be tested to ensure it is safe to use

Sewer pipe installation

WORKS IN THIS STAGE IN ACCORDANCE WITH

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STAGE 2

Blinding concrete is poured in preparation for the next stage.

SECTION

FOUNDATION SYSTEMS : SERVICES As the trenches have been made for the services to be laid out, pipes will be placed in the trenches and then backfilled and capped.

Key steps in this stage are : • In ground services and existing pipes are capped.

• Underground piping and services are laid - laying out the new services.

• Site will be backfilled to cover and protect the services.

• Compact fill has been brought onto site.

• Pouring of the blinding concrete. Blinding concrete poured to reach ground of adequate bearing capacity

In the image, the trench has already been dug and compact fill brought in, preparing for the pouring of the blinding concrete.

Service pipes are installed, backfilled and capped.

Fill is brought onto site and compacted as per the engineer’s specifications.

WORKS IN THIS STAGE IN ACCORDANCE WITH AS 3500.1 Plumbing and Drainage - Water Services AS 3500.2 Plumbing and Drainage - Sanitary Plumbing and Drainage AS 3500.3 Plumbing and Drainage - Heated Water Services AS 3500.3 Plumbing and Drainage - Stormwater Drainage

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STAGE 3

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PLAN

FLOOR SYSTEMS In the third stage, the site has been prepared so that the foundations and concrete slabs are ready to be poured.

Traditional timber formwork is built on site out of timber and plywood. Edge rebates and set downs are established with the formwork. In some areas, there is a gap under the formwork to allow the concrete to flow through and form the edge rebate. Formwork is left in position for a minimum of 28 days after the pouring of concrete.

Concrete pump on site to pour the concrete once the engineer inspection has been conducted.

Concrete is mechanically vibrated and trowelled in accordance with AS 3600. This is done to make the concrete flat and smooth,

Reinforcement mesh and hollow polystyrene blocks are installed, ready for the concrete to be poured. Rebar spaces are used to keep the reinforcement in place.

Reinforcement mesh is installed with rebar spaces.

0.2mm waterproof polyethylene membrane is installed.

Set down in slab to allow for falls in wet areas.

Polystyrene void formers are installed.

The use of the polysytrene void formers helps minimise the use of concrete and increases the construction efficiency.

Before the concrete is poured, a slump test is conducted on site to determine the workability of the concrete mix.

Trenches have been dug by the excavators. https://gharpedia.com/concrete-slump-test-to-check-workability/ ABPL20033 - 2019, Natalie Ang | 996016 |Tutorial 6 | Anastasia Sklavakis | p. 6

WORKS IN THIS STAGE IN ACCORDANCE WITH

STAGE 3

Before the concrete is poured, the engineer must conduct an inspection.

SECTION

FLOOR SYSTEMS

A concrete truck is brought onto site. Concrete is pumped into the formwrok, vibrated, troweled and floated to achieve a level finish

In this stage, the foundations and concrete slabs are ready to be poured. A concrete truck, concrete pump and boom are used to pour the concrete. The concrete is then levelled with a trowelling machine and the surface is finished with a stand up trowel.

Key steps in this stage are : • Timber formwork constructed on site for slab edges and set downs. Rebates, falls and set downs are established.

• Fill brought into the site in layers and compacted as per the engineering specifications • Sand bed laid • Waterproof membrane is installed • Polystyrene void formers are installed and reinforcement mesh laid out in preparation for the pouring of the concrete.

• Chairs and reinforcing mesh are installed.

• Base plates for steel work are cast in, in preparation for the next stage - the structural systems.

• Engineer inspection is conducted prior to the concrete being poured • Concrete is pumped with a concrete truck into formwork and then vibrated, troweled and floating to achieve the level finish • Concrete is poured and then cured for a minimum of 7 days.

Rebate in the slab is established for the bricks. The formwork is constructed to allow for slab edges and set downs. A 2 brick rebate is installed.

A

50mm sand bed is laid to specification and a 0.2mm waterproof polyethylene membrane is installed. The waterproof membrane helps prevent moisture infiltration.

Polystyrene void formers are installed and reinforcement mesh laid over it in preparation for the concrete pour. The use of the polysytrene void formers helps minimise the use of concrete

Fill brought into site in layers and compacted as per the engineer’s specifications.

A Reinforcement bars are installed in accordance with AS3600 15 MPa blinding concrete founded 200mm min. in stiff clay. Blinding concrete functions as the bridge between the ground and the slab, transferring the load to the ground.

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STAGE 4

A

PLAN

Bolts

STRUCTURAL SYSTEMS Once the concrete floor system has been completed, the next stage is to complete the building frame. During this stage, structural steelwork is brought to site with cranes and the structural timber frames are then installed.

Bottom plate

Beam to beam connection Cleat plate

A crane is brought onto site to install the structural steelwork. Other machinery, such as a scissor lift, are also used on site to help lift workers up to higher heights.

Two parallel flange channel (PFC) connection using a 10mm cleat plate that is bolted to the beam.

Cap plate bolted to the top of the column. Column is joined to the beam through a 10mm cleat plate which is bolted.

A Lintels are installed, helping to carry the load over windows and distribute these loads to the jamb studs on either side.

Columns are bolted to the concrete slab.

1.0mm deep steel trusses are brought onto site and installed with the crane. These were prefabricated and transported to site.

Timber stud frames are assembled and installed on site. This is done by trimming the timber and assembling the members on the ground first. It is then pushed upright, leaving the temporary supports in place to keep the frame upright.

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STAGE 4

SECTION

STRUCTURAL SYSTEMS

Cap plate bolted to the top of the steel column. Cap plates help to adequately transfer large loads.

The materials and installation of the structural steelwork must comply with AS4100 structures code

This stage consists of installing and preparing the building’s frame and structure. In this build, there are both lightweight and structural steel and welded and bolted connections.

Carpenters are also involved during this stage to install the main timber frame work of the building.

Key steps in this stage are : • Structural steel members are transported to site with a crane.

• Steel columns are bolted to the concrete slab. These are cast into anchor plates. In this build, the architect’s wanted a smooth transition, as such, the steel columns were placed flush with the ground and cast with a base plate.

• Steel members are welded to cleat plates • Lintels are installed due to the availability of the crane on site. This will also help the builder to understand where the brickwork lies when doing masonry.

• Bottom plates and timber stud frames are installed • Noggings are fixed in between the studs • Metal straps are looped over top plate and strapped

A Steel column

Cast in plate

Anchor bars

Timber stud frames are assembled and installed on site. The carpenter will trim the timber and assembling the members. Noggings help to strengthen stud walls, stopping them from bowing under lateral loads. Metal bracing helps to provide rigidity and stability to the wall frames.

Crane installs structural steel elements - in this case, the prefabricated steel truss.

For aesthetic reasons, following the architect’s specifications, the steel columns are placed so that they are flush with the ground. The columns are bolted to the concrete slab. It is then cast in with a base plate that has been galvanised, which helps to prevent rust and corrosion. Anchors bars will help to anchor the plate to the concrete slab.

A

Scissor lifts are brought onto site to help workers to reach higher levels.

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STAGE 5

PLAN

INTERMEDIATE FLOOR STRUCTTURE In this stage, the intermediate floor structure is ready to be installed.

Once this has been completed, workers are able to continue with the structural framing on the first level.

Timber structural framing is still ongoing once the intermediate floor structure is being completed. Timber studs are assembled flat for ease of construction before being pushed upright

Scaffolding has been erected around the perimeter of the first floor for the safety of the workers. It also allows workers to access and work in areas they are unable to get to with the intermediate floor structure

19mm yellow tongue structural flooring installed to brace the floor.

Carpenter on site trimming the timber members and assembling the members together.

Flooring underlay will be installed on top of the floor joists to provide a working surface and to later install the floor finishes.

Posi struts are supported by the floor joists which are bolted to the steel beams.

Framing out of the windows

Soffit is installed over breathable sarking on 19mm marine plywood. 19mm yellow tongue structural flooring is then installed to brace the floor.

Temporary supports to keep the stud walls upright.

TImber structural framing is still ongoing during this construction phase. Now that the floor structure of the first level and sub floor of the level is installed, workers are able to continue working on the timber structural framing as there is a working platform.

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STAGE 5

SECTION

INTERMEDIATE FLOOR STRUCTTURE This stage consists of installing the intermediate floor structure.

This is done once the external walls and structural framing of the ground floor has been completed. By constructing the intermediate floor structure, it creates a working platform.

Key steps in this stage are : • Temporary railings and scaffolding are erected • Building the structural deck - in accordance to the structural drawing S03, floor joists and bearers are placed • Floor joists are connected to other timber members with a joist hanger • In order for floor joists to attach to the I beam, timber beams are placed inside the I beams • Trusses are attached to UB with a joist hanger that is fully nailed • Yellow tongue structural flooring is installed to brace the floor • Timber is delivered to site in preparation for the next phase the roof system

Posi struts are supported by the floor joists which are bolted to the steel beams.

Scaffolding erected around the perimeter of the first floor for safety reasons.

It also allows workers to access and work in areas they are unable to get to with the intermediate floor structure

A 120mm thermal insulation installed between the floor joists

19mm yellow tongue flooring with carpet finish on top of it

A

Ceiling battens spaced at 450mm centres

Soffit lining

Section detail of the first floor structure.

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STAGE 6

PLAN

ROOF SYSTEM : ROOF STRUCTURE & COVER The building frame has been completed, with the structural elements installed and intermediate floor structure established. The construction of the roof structure will commence during this phase. In this stage, the roof framing system is laid out as per the structural drawing S04.

Before the insulation is installed, wire mesh is put in place after the timber framing. The roof insulation will be installed between the battens.

Sarking is installed and taped down. The sarking wraps around the exterior of the frame after the timber frame, wire mesh and insulation has been installed. It’s fixed to the structural framing and taped to be sealed.

In preparation for the roof finish to be installed on top of the sarking, there are fixing clips on top of the sarking. This will allow the zinc to be screwed into place.

Rafters, battens and roof trusses are laid out to create the framing of the roof. This is in preparation of installing the roof sheeting, which will be fixed to the rafters and battens. Bracing is also installed.

Framing out of the box gutter so that the gutter can sit on the plywood framing. The box gutter is installed before the roof sheeting is overlaid.

Wire mesh is installed before the insulation goes in. The wire mesh helps to hold the insulation in place and is there for safety reasons.

After the wire mesh is installed, insulation is installed. In this case, 210mm thermal insulation is used for thermal comfort and performance.

Sarking is installed in both the roof and walls for efficiency as they will be clad in the same material. The green underlay in the sarking allows for the cladding to expand and contract and also helps to hold the zinc cladding in place to avoid warping. Sarking is used for waterproofing and is taped down using special tape

Rafters spaced at 450mm centres.

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STAGE 6

Box gutters are installed on 19mm plywood. The roof sheeting will be overlaid after so that it can sit over the box gutter

SECTION

ROOF SYSTEM : ROOF STRUCTURE & COVER This stage consists of laying out the timber beams, battens and rafters to construct the roof structure, installation of cladding and the framing out for box gutters and other gutters. For the roof structure, there is a combination of both a structural steel system and timber used to create the framing of the roof.

Materials such as zinc roof sheeting are delivered to site in prepation for the next phase of construction - installation of cladding.

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B A

Key steps in this stage are : • Scaffoldings are installed • Timber beams and rafters are laid out • Timber roof battens are placed on top of the rafters • Prefabricated roof truses are brought onto site and installed.

Trusses are attached to PFC • Box gutter is framed out • Installation of insulation and wire mesh - roof insulation is installed between battens • Sarking is installed and taped down with green / blue tape • Zinc roof sheeting is delivered to site and installed, fixed to fixing clips

Rafters spaced at 450mm centres. 140mm x 45mm timber roof battens are then placed on top of the rafters, spaced to suit the specified roofing.

B Thermal insulation

Materials have been delivered to site in prepation for the next phase of construction, which is cladding. Bricks should normally be stored on pellets as they are porous, however, in this case, the bricks were left on the ground as they installed it soon after the delivery.

Zinc metal roofing over 19mm plywood

Battens at 450 centres Thermal insulation - gold ceiling batts

A

13mm plasterboard (water resistant)

Section of ceiling make-up.

Insulation is installed in both the ceiling and roof. Thermal insulation is used in these locations to prevent the transmission of heat, as the roof of a home loses heat quickly.

Box gutter with a zinc finish sitting on 19mm plywood. Roof sheeting that is overlaid after the box gutter is installed is designed in a way to prevent water from running on the underside.

Flash capping over the edge of the roof. This helps to bring the water down to the box gutter and the flashing also prevent water running on the underside.

Roof framing system laid out as per the structural drawing S04.

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STAGE 7

PLAN

WALL SYSTEMS : EXTERNAL WALLS & CLADDINGS

Before the insulation is installed, wire mesh is put in place after the timber framing. The roof insulation will be installed between the battens.

Once the roof framing has been completed, the external cladding will be installed. In this stage, waterproofing techniques will also be used to keep water away from the building.

Blend of the bricks are confirmed.

Grampian blue dark blend bricks were chosen. These will be stacked in a stretcher bond with raked brick joints and mid grey coloured mortar.

Box gutter installed in the previous stage, prior to the roof sheeting being installed. This is to allow the water to fall from the roof into the box gutter.

A Articulation Joint Weep hole

Internal and external brickwork is installed. Back door is framed out in preparation for the next stage when the doors, windows and glazing are installed.

Articulation joints and weep holes are included and considered when laying the brickwork.

Articulation joints allow and cater for movement of the materials as well as movement caused by other factors such as movement in the foundations.

The zinc roof sheeting is delivered to site, ready to be installed. The sheeting comes with a protective layer to protect the product before it is installed.

Weep holes are important as they allow water to escape and allows the building to breathe by letting in airflow and ventilation.

A

Zinc roof sheeting is screwed and fixed to the sarking with fixing clips.

This is done after the installation of the insulation and roof.

Framing out of the openings and windows in preparation for the next stage of construction when the glazing and window frames are brought in.

Once the blend of the bricks have been approved and confirmed, bricks are then delivered to site and installed.

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STAGE 7

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SECTION

WALL SYSTEMS : EXTERNAL WALLS & CLADDINGS In stage seven, the roof sheeting and brick masonry is installed for the house.

Key steps in this stage are : • Brick wall prototyping to test the strength and confirm the blend of the bricks • Bricks, timber cladding and roof sheeting are delivered to site, ready to build the external walls • Windows and openings are framed prior to executing the cladding • In this build, as the masonry wall wraps around the interior of the house, the external and internal brick wall was constructed at the same time • Brick walls are installed, including brick ties, weep holes and articulation joints • The perimeter of the building is capped.

• Flash capping over the edge of the roof to help bring water down to the box gutter • Capping installed over brick wall with sarking in the interior of the brickwork • Sarking installed on timber stud frames for moisture protection

C

B Sarking Brick

OUTSIDE

C B

120mm thermal insulation

INSIDE

13mm Plasterboard (water resistant)

Thermal insulation

INSIDE

OUTSIDE

Wall type make up. The exterior brick wall will have a weep hole to drain water and help to ventilate the internal wall cavity. Sarking helps to prevent condensation forming and protect moisture from penetrating.

19mm plywood fixed to studs

Sarking

Zinc sheet

Wall type make up for the bedrooms. Plywood is fixed to the stud, sarking is then installed and the zinc sheet is then fixed to the plywood.

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STAGE 8

PLAN

WINDOW SYSTEMS In this stage, vacuum glass lifting equipment and cranes are brought onto site to lift large panes of glass onto the first floor for installation. This stage requires numerous workers on site to help in lifting and positioning the glass as it is quite heavy.

Skylights being installed and flashed.

Timber frame of the back door has been installed. Single glazed toughened glass has also been installed. The glass has been toughened so that the dog door could be cut out.

Vacuum glass lifting machine has been brought onto site to help lift large panes of glass.

Skylights are also installed in this stage. Flashing is installed around the skylight to prevent water penetration.

Window sill will be sealed by caulking to prevent water leaks.

Glazing must comply with AS1288.

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STAGE 8

SECTION

WINDOW SYSTEMS This stage consists of installing the windows and doors. Window frames are installed into the stud walls. Once the windows have been placed and sealed, the building is then water tight and ready for the next stage - internal partitions and ceiling structure.

Key steps in this stage are : • Ongoing prototyping for windows to ensure they are suitable.

• Window frames are made out of timber and installed • Glazing is brought in and installed by a crane.

• Window sills will be sealed to prevent water penetration.

• Flashing and caulking installed on all window and door frames to prevent the ingress of water into internal areas.

A

A

Timber framed double glazed awning window with internal flyscreen installed for the bedroom.

Zinc window head flashing down turned 20mm

13mm water resistant plasterboard Timber framed double glazed awning window with internal flyscreen

Timber framed door frame with single glazed toughened glass

Zinc flashing into notch in underside of sill to prevent water penetration

Timber framed double glazed sliding window.

Section detail of the window in the bedroom.

Flashing at both the head of the window and window sill preventing water penetration.

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STAGE 9

PLAN

INTERNAL PARTITIONS & CEILING STRUCTURE

One side of the wall will have the plasterboard installed. These will be fixed with screws. Before the other side can be closed, the architects have to inspect it.

In this stage, insulation is installed into the walls and the internal partitions are constructed. Bulk insulation is installed into the wall cavity before the wall is closed with plasterboards. Rough ins also occur at this stage.

Electrical installation carried out in two parts - rough in and fix off. In this stage, the rough in happens. The structure of the services are in place but they are not concealed by the finishes yet.

Insulation is installed in the walls and ceilings. This includes both insulation for thermal performance and insulation for acoustic performance.

Rough in wiring consists of placing all the main electrical cables throughout the building.

They will later be concealed in the next stage.

Assembly of the timber stud partition wall. Top and bottom plates are fixed to the floor and ceiling.

Insulation inserted into the walls.

The thermal insulation will help to add thermal comfort by retaining heat in the winter.

Once the architects have checked and approved the internal partitions, the plasterboard can be fixed with screws on the timber stud wall, closing it. It is now ready for the next stage where the plasterboards are painted according to architect’s specifications.

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STAGE 9

SECTION

R2.5 Bradford Sounscreen Plus insulation installed between the timber stud walls

INTERNAL PARTITIONS & CEILING STRUCTURES This stage consists of installing the internal partitions and insulation. By this stage, the windows and doors have been installed and the house is now water tight.

Key steps in this stage are : • Internal partitions are installed - this includes timber framing being put into place. Top and bottom plates are fixed to the floor and ceiling.

• Plasterboards are affixed to one side of the timber stud frame. Plasterboards are fixed with screws.

• Insulation is installed in the walls • Rough ins of electrical and plumbing services occur.

• Architect has to check and approve the internal partitions before the wall is closed Plasterboards will be screwed to one side of the partition once the rough ins occur.

A

Bolt to joist

Galvanised metal straps nailed to plates with nails at each end

Timber framing for internal partitions are installed. The bottom plates are bolted to floor.

The bracing helps to provide stability to wall frames.

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STAGE 10

PLAN

SERVICES & FINISHING TRADES

Installing the final plasterboards once the architects have approved. This will conceal the services running through the walls and close up the internal partitions.

In this stage, small power tools are utilised to complete the final finishes and fixing on site. At this point, many different trades, such as painters, electricians, carpenters and plumbers will be on site, working on their respective areas.

Factory visits are conducted to find suitable fittings. Fittings are also made to the specifications in the architectural drawings.

Cabinetry installed in the hall.

They will also be installed in the laundry.

Brush stones are laid in the ground floor of the home. The re is a 2mm joint width and the grout colour is specified by the architects.

Carpet finish is installed over the structural flooring in the bedrooms.

Installation of appliances such as sinks. The plumbers will be on site to connect the services.

Appliances such as sinks are installed. Infloor heating is also installed in this stage.

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STAGE 10

SECTION

SERVICES & FINISHING TRADES This stage consists of applying the final finishes such as flooring and paint. Fittings such as cupboards are also installed as well as any other final detailing and joinery. This is the last stage before the handover occurs.

Key steps in this stage are : • Visits to factories are conducted to find suitable fittings • Installation of infloor heating • Closing of the internal partitions by affixing plasterboards.

• Painter paints over the walls according to the architect’s specifications.

• Floorboards are installed and finished.

• Doors, joineries and fittings are installed. These are created off site and brought in to be installed.

• Taps, sinks, baths and other appliances are installed and connected by the plumber.

• Inspection is conducted

Once the plasterboards have been installed, the painter will paint the walls in white - as specified by the architectural drawings.

A

Finish of the shelf is spotted gum timber veneer panels

Wool carpet is installed in the bedrooms.

Cabinetry is constructed and then delivered to site where they are arranged and placed in their correct location according to the architectural plan.

Fillet weld Outrigger welded

Scews

Shelf details in the bedroom. The timber veneer panels are applied to all surfaces of fixed shelves.

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