Building Technology l Industrialized Building System Report

SCHOOL OF ARCHITECTURE, BUILDING AND DESIGN BUILDING TECHNOLOGY 1 [BLD 61403/ ARC3514/ ARC3512] PROJECT 1: INDUSTRIALISED BUILDING SYSTEM PREPARED BY: 0323827 0326969 0327039 0326733 0323898

LAU HUI MING NG JER VAIN PRITIKA RAMA MOHAN LIM SIEW NI NG XIAN LE

TUTOR: TS. MOHAMED RIZAL MOHAMED

TABLE OF CONTENT

01 INTRODUCTION 02 PRECEDENT STUDIES 03 ARCHITECTURAL DRAWINGS 3.1 ARCHITECTURAL PLAN 3.2 ROOF PLAN 3.3 STRUCTURAL PLAN 3.4 ELEVATIONS 3.5 SECTIONS 3.6 AXONOMETRIC 3.7 SECTIONAL PERSPECTIVE 3.8 DETAIL DRAWINGS 3.8.1 FOUNDATION 3.8.2 COLUMNS AND BEAMS 3.8.3 FLOOR SLAB DETAIL 3.8.4 ROOF DETAIL 3.8.5 STAIRCASE DETAIL 3.8.6 TOILET POD DETAIL 04 COMPONENT SCHEDULE 4.1 BEAM 4.2 COLUMN 4.3 SLAB 4.4 WALL 4.5 TRUSS 4.6 WINDOW 4.7 DOORS

05 IBS SYSTEMS 5.1 PRECAST CONCRETE SYSTEM 5.1.1 FOUNDATION 5.1.2 PRECAST COLUMN 5.1.3 PRECAST BEAM 5.1.4 PRECAST SLAB SYSTEM 5.1.5 PRECAST FOUNDATION TO COLUMN CONNECTION DETAIL 5.1.6 PRECAST BEAM TO COLUMN CONNECTION 5.1.7 PRECAST SLAB TO BEAM CONNECTION 5.1.8 PRECAST SLAB TO WALL CONNECTION 5.1.9 PRECAST STAIRCASE 5.1.10 PRECAST TOILET 5.2 BLOCKWORK SYSTEM 5.2.1 EXTERNAL WALL & INTERNAL WALL 5.3 STEEL FRAMING SYSTEM 5.3.1 ROOF TRUSS 5.3.2 CONNECTIONS AND JOINTS OF ROOF TRUSS 5.3.3 LAYERS OF ROOFINGS 06 SEQUENCE OF CONSTRUCTION 6.1 BIM DIGITAL CONSTRUCTION PROCESS 6.2 MODEL CONSTRUCTION PROCESS 07 IBS SCORE CALCULATION 7.1 SPECIFICATION 7.2 CALCULATION 08 CONCLUSION 09 REFERENCE

INTRODUCTION

1

01 INTRODUCTION The construction industry in Malaysia is experiencing a migration from conventional methods to a more systematic and mechanised method known as the Industrialised Building System (IBS). Each state in Malaysia is currently examining the developments of the IBS and its potential to overcome the shortages of housing accommodations in this country. The Malaysian government, involved through its agency, the Construction Industry Development Board (CIDB) has been persistently pushing the construction industry to utilise of the IBS method of construction since 2003. It is a part of an incorporated endeavour to further improve the aptitude, potential, effectiveness and competitiveness of the industry as well as to diminish the industry's dependence on foreign labour Industrialised Building System (IBS) is a technique of construction whereby components are manufactured in a controlled environment, either at site or off site, and transported, positioned and assembled into construction works. In Malaysia, they are divided into 6 categories : 1.

2.

3.

4.

5.

Precast System Steel Framing System Formwork System Blockwork System Pre-fabricated Timber Framing

Based on the categories, we will design a 3-storey apartment block and document our understanding in this report.

PRECEDENT STUDIES

2

02 PRECEDENT STUDIES 2.1 2 Seri Jati Apartment, Setia Alam Located in Shah Alam ,Selangor is Seri Jati low cost apartment .This project by SP Setia was developed for the below average income citizens. Launched in 2012, this high density apartment project was completed in 2014. The layout consists of 6 blocks in total where 3 blocks are 10 storey high and the remaining 3 blocks are 11 storey high. In total making up to 948 units.

Image 2.2: Pool view of Seri Jati apartment

Image 2.1: Seri Jati apartment construction This apartment uses precast concrete system with precast component such as precast load bearing walls, precast non -load bearing walls ,precast staircases and landing slabs ,precast lift core walls ,precast bathroom slabs and precast air cond ledges. It also uses prefabricated steel trusses for the roof .

Floor slab fo this apartment are cast-in situ slabs. It has a total of 81.9 IBS score.

The use of IBS in this apartment has reduced construction time ,number of construction workers and also cost.

Image 2.3 Front view of Seri Jati Apartment

ARCHITECTURAL DRAWINGS

3

03 ARCHITECTURAL DRAWINGS 3.1.1 Ground Floor & First Floor Plan

Diagram 3.1 Ground floor and first floor plan

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.1 2 Second Floor Plan

Diagram 3.2 Second floor plan

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.2 Roof Plan

Diagram 3.3 Roof plan

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.3 Structural Plan

Diagram 3.4 Structural plan

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.4.1 North Elevation

Diagram 3.5 North elevation

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.4.2 South Elevation

Diagram 3.6 South elevation

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.4.3 East Elevation

Diagram 3.7 East elevation

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.4.4 West Elevation

Diagram 3.8 West elevation

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.5.1 Section A-A’

Diagram 3.9 Section A-A’

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.5.2 Section B-B’

Diagram 3.10 Secton B-B’

ll Scale 1:150

03 ARCHITECTURAL DRAWINGS 3.6 Exploded Axonometric Roof Purlin Truss Ceiling Slab Ceiling Beam

Column Walls Slab Beam Doors and Windows Precast Staircase and Toilet Pods

Ground Floor and First Floor

Foundation Footing ll Scale 1:450 Diagram 3.11 Exploded axonometric

03 ARCHITECTURAL DRAWINGS 3.7 Sectional Perspective

ll NTS Diagram 3.12 Sectional persepective

03 ARCHITECTURAL DRAWINGS 3.8.1 Detail Drawings - Pile Foundation

Diagram 3.14 MS shoe detail

Diagram 3.13 Section through pile, pile cap and column

03 ARCHITECTURAL DRAWINGS 3.8.2 Detail Drawings - Columns & Beams

Diagram 3.15 Column detail

Diagram 3.16 Beam and column connection detail

03 ARCHITECTURAL DRAWINGS 3.8.3 Detail Drawings - Floor Slab detail

Diagram 3.17 Floor slab detail

Diagram 3.18 Floor slab detail

03 ARCHITECTURAL DRAWINGS 3.8.4 Detail Drawings - Roof Details

Diagram 3.19 Roof detail

Diagram 3.20 Roof detail

03 ARCHITECTURAL DRAWINGS 3.8.5 Detail Drawings - Staircase Detail

Diagram 3.21 Staircase plan view

Diagram 3.22 Staircase detail

03 ARCHITECTURAL DRAWINGS 3.8.6 Detail Drawings - Toilet Pod Details

Diagram 3.22 Toilet pod detail

Diagram 3.23 Toilet pod section

COMPONENT SCHEDULE

4

04 COMPONENT SCHEDULE 4. 1 Beam Schedule LEFT ELEVATION

FRONT ELEVATION

PLAN

Name: L Beam

Name: L Beam

Name: L Beam

Dimension (L x W x H): 4100mm x 250mm x 400mm

Dimension (L x W x H): 6210mm x 250mm x 400mm

Dimension (L x W x H): 3020mm x 250mm x 400mm

Quantity : 8

Quantity : 16

Quantity : 16

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

04 COMPONENT SCHEDULE 4.1 Beam Schedule LEFT ELEVATION

FRONT ELEVATION

PLAN

Name: L Beam

Name: L Beam

Name: L Beam

Dimension (L x W x H): 3800mm x 250mm x 400mm

Dimension (L x W x H): 4100mm x 250mm x 400mm

Dimension (L x W x H): 4215mm x 250mm x 400mm

Quantity : 8

Quantity : 16

Quantity : 6

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on one side.

04 COMPONENT SCHEDULE 4. 1 Beam Schedule LEFT ELEVATION

PLAN

FRONT ELEVATION

Name: T Beam

Name: T Beam

Dimension (L x W x H): 4215mm x 250mm x 400mm

Dimension (L x W x H): 6625mm x 250mm x 400mm

Quantity : 6

Quantity : 8

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on both side.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement and support slab on both side.

04 COMPONENT SCHEDULE 4. 1 Beam Schedule LEFT ELEVATION

PLAN

FRONT ELEVATION

Name: T Beam

Name: T Beam

Dimension (L x W x H): 4215mm x 250mm x 400mm

Dimension (L x W x H): 6625mm x 250mm x 400mm

Quantity : 16

Quantity : 16

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement.

04 COMPONENT SCHEDULE 4. 1 Beam Schedule LEFT ELEVATION

PLAN

FRONT ELEVATION

Name: Rectangular Beam

Name: Rectangular Beam

Dimension (L x W x H): 2870mm x 250mm x 400mm

Dimension (L x W x H): 850mm x 250mm x 400mm

Quantity : 8

Quantity : 8

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement.

Specification Preferred size beam according to MS 1064 Part 10: 2001 with rebars as reinforcement.

04 COMPONENT SCHEDULE 4. 2 Column Schedule PLAN

LEFT ELEVATION

FRONT ELEVATION

Name: Precast Concrete Column (4 extrusion)

Name: Precast Concrete Column (3 extrusion)

Name: Precast Concrete Column (2 extrusion)

Dimension (L x W x H): 3600mm x 250mm x 400mm Dimension (L x W x H): 3600mm x 250mm x 400mm Dimension (L x W x H): 3600mm x 250mm x 400mm Quantity : 6 Quantity : 18 Quantity : 36 Specification Preferred size column according to MS Specification Preferred size column according to MS Specification Preferred size column according to MS 1064 Part 10: 2001 with rebars as reinforcement.

1064 Part 10: 2001 with rebars as reinforcement. 1064 Part 10: 2001 with rebars as reinforcement.

04 COMPONENT SCHEDULE 4. 3 Slab Schedule PLAN

ELEVATION

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Dimension (W x D x L): 625mm x 150mm x 3000mm

Dimension (W x D x L): 1200mm x 150mm x 3000mm

Dimension (W x D x L): 950mm x 150mm x 4250mm

Quantity : 4

Quantity : 20

Quantity : 8

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

04 COMPONENT SCHEDULE 4. 3 Slab Schedule

PLAN

ELEVATION

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Dimension (W x D x L): 500mm x 150mm x 4845mm

Dimension (W x D x L): 1200mm x 150mm x 4845mm Dimension (W x D x L): 1200mm x 150mm x 5945mm

Quantity : 8

Quantity :24

Quantity : 40

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

04 COMPONENT SCHEDULE 4. 3 Slab Schedule

PLAN

ELEVATION

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Dimension (W x D x L): 620mm x 150mm x 5945mm

Dimension (W x D x L): 1200mm x 150mm x 5880mm Dimension (W x D x L): 1200mm x 150mm x 5945mm

Quantity : 8

Quantity :8

Quantity : 8

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

04 COMPONENT SCHEDULE 4. 3 Slab Schedule

PLAN

ELEVATION

Name: Hollow core concrete slab

Name: Hollow core concrete slab

Dimension (W x D x L): 1080mm x 150mm x 5880mm

Dimension (W x D x L): 950mm x 150mm x 4250mm

Quantity : 8

Quantity :8

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

Specification Preferred size reinforce concrete slab according to MS1064 Part 10: 2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness: 150mm

Thickness: 150mm

Quantity : 4

Quantity : 4

Quantity : 4

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Thickness: 150mm

Quantity : 6

Quantity : 8

Quantity : 6

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Thickness: 150mm

Quantity : 6

Quantity : 12

Quantity : 4

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Thickness: 150mm

Quantity : 6

Quantity : 6

Quantity : 8

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule

ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Quantity : 6

Quantity : 4

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule

ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Quantity : 4

Quantity : 4

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule

ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Quantity : 4

Quantity : 6

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule

ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Quantity : 4

Quantity : 6

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Wall Schedule

ELEVATION

Name: Concrete block wall

Name: Concrete block wall

Thickness: 150mm

Thickness : 150mm

Quantity : 4

Quantity : 6

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 4 Walls

ELEVATION

Name: Concrete block wall Thickness: 150mm Quantity : 4 Specification Preferred size for walls thickness is according to MS1064 Part 10 :2001

04 COMPONENT SCHEDULE 4. 5 Truss Schedule

Name: Steel roof truss

Name: Steel roof truss

Dimension (L x W x H): 5100mm x 75mm x 1045mm

Dimension (L x W x H ):2860mm x 75mm x 630mm

Quantity : 20

Quantity : 4

Specification : err give me time to think

Specification : err

04 COMPONENT SCHEDULE 4. 6 Window Schedule PLAN

ELEVATION

Name: Glass window

Name: Glass window

Name: Toilet window

Dimension (L x W x H): 1800mm x 150mm x 1200mm

Dimension (L x W x H): 1800mm x 150mm x 1200mm

Dimension (L x W x H): 600mm x 150mm x 1200mm

Quantity : 8

Quantity : 16

Quantity : 12

Specification Preferred size window according to MS 1064 Part 5: 2001 with aluminium frame, repeated In vertical floor layout

Specification Preferred size window according to MS 1064 Part 5: 2001 with aluminium frame, repeated In vertical floor layout

Specification Preferred size window according to MS 1064 Part 5: 2001 with aluminium frame, repeated In vertical floor layout

04 COMPONENT SCHEDULE 4. 7 Door Schedule PLAN

ELEVATION

Name: Three panel sliding door

Name: Wooden frame door

Name: Wooden frame door

Dimension (L x W x H): 3300mm x 100mm x 2900mm

Dimension (L x W x H ):800mm x 100mm x 2100mm Dimension (L x W x H ):900mm x 100mm x 2100mm

Quantity : 6

Quantity : 12

Quantity : 24

Specification : 3 panel glass sliding door

Specification : Preferred size door according to MS 1064 Part 4: 2001

Specification : Preferred size door according to MS 1064 Part 4: 2001

IBS SYSTEM:

PRECAST CONCRETE SYSTEM

5

05 IBS SYSTEM 5.1.1 FOUNDATION : DRIVEN CAST-IN SITU CONCRETE A driven pile is a relatively long, slender column, provided to offer support or to resist forces, made of preformed material having a predetermined shape and size that can be physically inspected prior to and during installation, which is installed by impact hammering, vibrating or pushing into the earth.

ADVANTAGES

DISADVANTAGES

1. Piles can be precast to the required specifications.

1. Precast or prestressed concrete piles must be properly reinforced to withstand handling stresses during transportation and driving.

2. Piles of any size, length and shape can be made in advance and used at the site. As a result, the progress of the work will be rapid.

3. A pile driven into granular soil compacts the adjacent soil mass and as a result the bearing capacity of the pile is increased.

4. Driven piles may conveniently be used in places where it is advisable not to drill holes for fear of meeting ground water under pressure.

2. Advance planning is required for handling and driving.

3. Requires heavy equipment for handling and driving.

4. Since the exact length required at the site cannot be determined in advance, the method involves cutting off extra lengths or adding more lengths.

This increases the cost of the project.

CONSTRUCTION PROCESS

Diagram 5.1 Pile foundation

1.Implantation of the pile and positioning of the tube.

2. Top-driving the temporary steel tube into the soil with a hydraulic or Diesel hammer.

3. After reaching the required installation depth,driving is stopped and reinforcement is inserted.

4. Filling of the tube with concrete.

Concreting is done by means of a concrete transfer bucket ('cufa') fixed on the steel tube.

5.Withdrawal of the steel tube and finished driven cast-in-place pile

05 IBS SYSTEM 5.1.2 COLUMN : PRECAST SYSTEM Columns are rigid, relatively slender structural members designed primarily to support axial compressive loads applied to the ends of the members.Columns are frequently used to support beams or arches on which the upper parts of walls or ceilings rest.

ADVANTAGES

DISADVANTAGES

1.Since precast is manufactured in a controlled casting environment it is easier to control the mix, placement, and curing.

1. Sophisticated Connection Works

2.Quality can be controlled and monitored much more easily.

2. Usually, precast components are large and heavy, creating difficulties in transportation.

3. Precast concrete system is not flexible when future modification is taken into account.

3.Weather is eliminated as a factor-you can cast in any weather and get the same results, which allows you to perfect mixes and methods 4.On site, precast can be installed immediately, there is no waiting for it to gain strength and the modularity of precast products makes installation go quickly.

FABRICATION PROCESS

Diagram 5.2 Precast column

1.The customized column mould is assembled.

2. Fixing the rebars to the mould and adding sufficient amount of spacers and the correct size.

3. After the details are verified , concrete is poured for casting.

4. Once the concrete is cured the mould is loosen by removing the bolts and pins before lifting.

05 IBS SYSTEM 5.1.3 BEAM : PRECAST CONCRETE SYSTEM Beams are rigid structural members designed to carry and transfer transverse loads across space to supporting elements. The beam are usually supported by two columns to transfer the weight to the column which will direct to the foundation.

ADVANTAGES

DISADVANTAGES

1.Concrete beams are relatively strong in torsion when compared to structural-steel beams.

1.Joints between panels are often expensive and complicated.

2.Also concrete beams requires a lesser structural requirement on the connection and makes it easier during erection.

3.Minimizes joints compared to other construction products. Concrete beams can also be reinforced with either prestressing strands or conventional reinforcing bars.

Diagram 5.3 Precast beam

2.Skilled workmanship is required in the application of the panel on site.

3.Economies of scale demand regularly shaped buildings.

FABRICATION PROCESS

1.The customized beam mould is assembled.

2. Fixing the rebars to the mould and adding sufficient amount of spacers and the correct size.

3. After the details are verified , concrete is poured for casting. Once the concrete is cured the mould is loosen by removing the bolts and pins before lifting.

05 IBS SYSTEM 5.1.4 SLAB SYSTEM : PRECAST CONCRETE SYSTEM A hollow core slab, also known as a voided slab or a hollow core plank is a precast slab of prestressed concrete typically used in the construction of floors in multi-story apartment buildings.

ADVANTAGES

DISADVANTAGES

1.The long hollow cores (voids) can be used to run mechanical and electrical equipment.

1. Slabs cannot be cut on site 2. Irregular shaped hollow core are costly

2. The long span capabilities in hollow-core slab provides long and clear spans, opening interior spaces in projects and allows designers to maximize functional layouts.

3. Slabs cannot be cut on site hence the dimensions must be accurate .

3.The high-strength hollow-core slabs can provide floors that support heavy loads.

Diagram 5.4 Precast hollow core slab

FABRICATION PROCESS

1.The customized column mould is assembled.

2. Fixing the rebars to the mould and adding sufficient amount of spacers and the correct size.

3. After the details are verified , concrete is poured for casting. Once the concrete is cured the mould is loosen by removing the bolts and pins before lifting.

05 IBS SYSTEM 5.1.5 FOUNDATION TO COLUMN CONNECTION DETAIL : PRECAST CONCRETE SYSTEM

1.

The connection of the column stump to the foundation is steel based plate joint.

2. Metal bearing plates fixed at the end of the column and anchor bolts are bolted in place.

3.After the columns are mechanically joined, the connection void are later grounted by high strength cement grout between elements to provide full bearing for the ground level.

05 IBS SYSTEM 5.1.6 BEAM TO COLUMN CONNECTION DETAIL : PRECAST CONCRETE SYSTEM

1.Regarding to the column to beam connection,the precast beams are set in place . The beams are set on a bearing pads on the column corbels.

2.Steel angled are wielded to the metal plates cast into the beam and column and the joint is grouted solid by high strength grout.

05 IBS SYSTEM 5.1.7 SLAB TO BEAM CONNECTION DETAIL : PRECAST CONCRETE SYSTEM

1. The hollow core floor panels are placed on the L-beam or the T-beams. The hollow core slabs are set on bearing pads ,which sits on top of the precast beam.

2. Steel reinforcing bars are inserted into slab keyways to span the joint , then the exposed joint is grouted solid.

05 IBS SYSTEM 5.1.8 SLAB TO WALL CONNECTION DETAIL : PRECAST CONCRETE SYSTEM

Diagram 5.5 Slab to wall connection detail

1.

The reinforced bar is bent at 90’ angle .

2.

One end of each reinforcing bar is placed into the voids in between the slab, while the other end points upwards and fits into the concrete block cell of the wall.

3.

Then the slab keyways and the block cell are fully grounted.

05 IBS SYSTEM 5.1.9 PRECAST STAIRS : PRECAST CONCRETE SYSTEM

ADVANTAGES

DISADVANTAGES

1. High in quality control of finished product.

1.The measurements needs to be high in accuracy to ensure it fits perfectly.

2. Fast installation compared to cast in-situ.

3. Immediate use of the precast stairs hence suring time on site is needed .

2. Efficient vehicular transportation and lifting vehicles are needed.

INSTALLATION PROCESS 1.Steel brackets are bolted to the foundation using concrete anchors to attach the legs to the back of the stairs.

Diagram 5.6 Precast staircase

2. Small concrete pads are set under each side of the steps.

3.The precast stair is then placed on the brackets and secured carefully.

4.The railings are then installed on the precast unit and held in place with anchoring units.

Diagram 5.7 Staircase and landing connection

05 IBS SYSTEM 5.1.10 PRECAST TOILET : PRECAST CONCRETE SYSTEM

ADVANTAGES

DISADVANTAGES

1. Reduction of onsite building time by up to 80% compared to the construction of a traditional bathroom.

1.The measurements needs to be high in accuracy to ensure it fits perfectly.

2.Turn-key products, ready to install.

2.Chances of leakage when they are not installed properly and the second is, if they do not conform to the space.

3.Once the budget has been defined and the estimate has been approved, the cost will not change, allowing the client to optimise the investment.

INSTALLATION PROCESS

Diagram 5.8 Precast toilet pod

1. The precasted toilet pod is lifted and inserted into the compartment of the building.

2. The compartment is then grounted in place.

IBS SYSTEM:

BLOCKWORK SYSTEM

5

05 IBS SYSTEM 5.2.1 EXTERNAL WALL AND INTERNAL WALL : BLOCKWORK SYSTEM

ADVANTAGES

DISADVANTAGES

1. Versatile, durable and strong.

1.Low resistance to rain penetration

2. Completely fire resistant.

2.Lower sound insulation properties.

3. Excellent sound insulation.

3. Lower strength.

4. Ideal background for dry lining wet finishes and fixings.

5. Cost effective.

INSTALLATION PROCESS Diagram 5.9 Blockwork system wall 1. Lay Blocks Start mixing mortar mix as instructed. The first course of blocks should be installed below floor level and inside the foundation trench. This first line of concrete blocks shall rest on top of a layer of mortar mix.

2. Installing the Second Course on a Concrete Block Wall Repeat the action performed in the previous step to add another course of blocks.

Blocks can be set in such way that will create an interlocking pattern meaning that the ends of one course of blocks sit above the center of the blocks beneath them.

3. Cut Concrete Blocks Concrete blocks at one point will need to be cut so they can be installed in corners and along joints.

Diagram 5.10 Blockwork system wall detail

4. Structural Masonry Walls Vertical reinforcement can be installed within the block cells and filled with mortar.

Horizontal reinforcement might be needed as well, using prefabricated welded wires that are placed along the horizontal joints of in between courses.

IBS SYSTEM:

STEEL FRAMING SYSTEM

5

05 IBS SYSTEM 5.3.1 ROOF TRUSS : STEEL FRAMING SYSTEM

ADVANTAGES

DISADVANTAGES

1. The steel is manufactured under factory conditions and fabrication also will be done in steel yards or in factories. Hence the quality of materials and the accuracy of fabrication are very high.

1.Rusting 2.Lower sound insulation properties.

3. Lower strength.

2. Less work at the construction site.

3. Flexibility

FABRICATION PROCESS Diagram 5.11 Roof truss

1. Cutting Fabricators use several tools to cut the steel of a truss, including high-tech equipment such as plasma cutters, lasers, and water jets.

2. Forming To form trusses, fabricators use both press baking and rolling.

3. Assembly Assembly is the final process. The manufacturer will need to know the truss type, location, wind exposure, span, desired roof slope, and more to correctly assemble and join the steel. This process includes welding pieces together, bringing the final product together to serve its intended purpose as a truss.

05 IBS SYSTEM 5.3.3 CONNECTIONS AND JOINTS OF ROOF TRUSS

Diagram 5.12 Steel purlin and steel truss

Diagram 5.13 Concrete to steel roof truss connection

Diagram 5.13 Galvanised steel Plates with roof truss

05 IBS SYSTEM 5.3.3 LAYERS OF ROOFING

Diagram 5.14 Roof layers

1. Kalzip standing seam sheet- Used to prevent transmission of water and to keep the structure they are protecting dry.

2. Insulation- To minimise the heat gain from outside.

3. Aluminium ST Clip- Designed to secure the kalzip profiled sheet.

4. Vapour control layer- Protect building from the consequences of condensation, 5. Structural roof deck- It is a cold formed corrugated steel sheet supported by gable frame. It used to support insulating membrane of a roof.

SEQUENCE OF CONSTRUCTION

6

06 SEQUENCE OF CONSTRUCTION 6.1 BIM Digital Construction Process

1. Foundation

4. Columns

2. Ground Beam

5.Beams

3. Ground Floor Slab

6. External Walls

06 SEQUENCE OF CONSTRUCTION 6.1 BIM Digital Construction Process

7. Internal Walls

10. Beams and Columns ( Repeat the process 4 and 5)

8. Windows and Doors

11. Walls and Slab with Doors and Windows (Repeated 6-9 )

9. Precast Staircase and Toilet Pod with Slab

12. Steps 10-11 are repeated for second floor

06 SEQUENCE OF CONSTRUCTION 6.1 BIM Digital Construction Process

13. Roof Trusses

14. Purlins

15. Metal Deck Roof

06 SEQUENCE OF CONSTRUCTION 6.2 Model Construction Process

Pad footings are constructed as foundation

Ground beams are installed and supported by paf footing

Ground floor slabs are added

Precast concrete are installed

Precast beams are placed on the columns

Walls, doors and windows components are installed

06 SEQUENCE OF CONSTRUCTION 6.2 Model Construction Process

First floor columns are installed

Second floor beams and columns are installed

First floor beams are installed

The process for installation of ground floor is repeated in second floor

Walls are then installed on second floor

Prefabricated steel truss are installed on the ceiling precast concrete beams

06 SEQUENCE OF CONSTRUCTION 6.2 Model Construction Process

Roofing materials are fixed onto the steel purlins

Precast toilet pods are installed into the building

Final model in 1:50 scale

Precast concrete staircase are installed into the building

IBS SCORE CALC ULATION

7

07 IBS SCORE CALCULATION 7.1 SPECIFICATION 1. Construction Area Ground floor : 239 m² First floor : 239 m² Second floor : 239 m² Roof : 326.4 m² Total construction area : 1043.4 m²

2. Structural System a. b. c. d.

Beams Columns Floor slabs Roof truss

: Pre-cast concrete beams : Pre-cast concrete columns : Pre-cast floor slabs :Steel frame roof truss

3. Wall System a.

Internal wall & external wall : Blockwork system

ELEMENTS

AREA (SQM)

IBS FACTOR

COVERAGE

IBS SCORE

Precast beams + Precast columns + Precast hollow core slabs Ground floor area : 239 m²

239 m²

1.0

(239/1043.4) = 0.23

0.23 x 1.0 x 50 = 11.45

Precast beams + Precast columns + Precast hollow core slabs First floor area : 239 m²

239 m²

1.0

(239/1043.4) = 0.23

0.23 x 1.0 x 50 = 11.45

Precast beams + Precast columns + Precast hollow core slabs Second floor area : 239 m²

239 m²

1.0

(239/1043.4) = 0.23

0.23 x 1.0 x 50 = 11.45

326.4 m²

1.0

(326.4/1043.4) = 0.31

0.31 x 1.0 x 50 = 15.64

1.0

50

(74.14/74.14) = 1

1 x 0.5 x 20 = 10

1.0

10

Part 1 : Structural Elements

Steel frame roof truss Roof truss area : 326.4 m² Total Part 1

Part 2 : Wall Systems Blockwork system

74.14 m

0.5

Total Part 2 Part 3 : Other Simplified Construction Solutions 1. 100% columns sizes complies to MS106 Part 10 : 2001

-

-

-

4

2. Repetition of floor to floor height

-

-

-

2

3. Horizontal repetition of structural floor layout

-

-

-

2

4. Horizontal repetition of horizontal floor layout

-

-

-

2

Total Part 3

10 70

CONCLUSION

8

We have learnt a lot of structural design and possibilities through this project.Not only it broaden our knowledge regarding mixed ibs system it also allowed us to do our own exploration and come up with a hybrid system. We have been also introduced to the IBS Score System (IBS Score) a systematic and structured assessment system that can be used to measure the usage of Industrialised Building Systems (IBS) in a consistent way.

For government projects the minimum IBS Score needed to be achieved is 70 points meanwhile, for private sector projects are 50 points. Our design has accumulated a total of 70 points out of 100 points which is a reflection of a reduction of site labour, lower wastage, less site materials, a cleaner environment, better quality, a neater and safer construction site, faster project completion, as well as lower total construction costs.

We now have a new respect and understanding of the structural members and their role in being capable to withstand the amount of load and also completing the whole building. We will definitely apply this knowledge when designing our next project.

REFERENCE

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Abhishek Gupta, Working Follow. (2015, April 03). PreCast Construction. Retrieved October 08, 2017, from https://www.slideshare.net/shekhu001/precast-construction Bathroom Pods and Shower Pods. (n.d.). Retrieved October 08, 2017, from https://www.eblcomposites.com/bathroom_pods.php Desk, N. (2015, November 24). Design of RC Beam Column Joints. Retrieved from https://www.masterbuilder.co.in/design-of-rc-beam-column-joints/ mbrsalman. (2018). Civil Engineering (Beams,Columns). Slideshare.net. Retrieved 29 April 2018, from https://www.slideshare.net/mbrsalman/civil-engineering-beamscolumns Method of Joints | Analysis of Simple Trusses | Engineering Mechanics Review. (2018). Mathalino.com. Retrieved 29 April 2018, from https://www.mathalino.com/reviewer/engineering-mechanics/method-joints-analysis-simple-trusses Mewada (2018). PRECAST CONCRETE STAIRS. [online] Slideshare.net. Available at: https://www.slideshare.net/abhishekmewada54/precast-concrete-stairs [Accessed 29 Apr. 2018].

Mishra, G. (2017, September 12). Types of Precast Components in a Building. Retrieved from https://theconstructor.org/concrete/types-of-precast-components-in-a-building/6325/ Precast Concrete Construction in Buildings. (n.d.). Retrieved from http://www.understandconstruction.com/precast-concrete-construction.html Pre-fab foundation beams. (n.d.). Retrieved October 08, 2017, from http://www.vroom.nl/en/products/5-pre-fab-foundation-beams (n.d.). Retrieved from http://www.cement.org/cement-concrete-applications/products/precast-concrete The Balance Small Business. (2018). Here Are Step-By-Step Instructions How to Build a Concrete Block Wall. [online] Available at: https://www.thebalancesmb.com/how-to-build-concrete-block-wall-844822 [Accessed 29 Apr. 2018]. →, V. (2018). What is a vapour control layer (VCL)? - Celotex Blog. Celotex Blog. Retrieved 29 April 2018, from http://blog.celotex.co.uk/technical/vapour-control-layer-vcl-celotex/