Building Technology 1 Report

BUILDING TECHNOLOGY 01 INDUSTRIAL BUILDING SYSTEM (IBS)

Goh Jyia Whey Jordan Tok Wen Xuan Khoo Yung Keat Tan Yang Wong Lieng Kam Tutor: Mr. Edwin

0324910 0327629 0324688 0328025 0323566

X Concept & Framework

Introduction of IBS System Types of IBS System Pros and Cons of Proposed IBS System Case Study

IBS Components

Cast In-situ Foundation Hollow Core Floor Slab Column & Beam Acotec Wall Panel Prefab Metal Roof Truss Prefab Concrete Staircase Toilet Pod

01 02

Technical Drawings Architectural Floor Plan Roof Plan Elevations Section A-A’ Section B-B’ Foundation Plan Structural Plan Structural Section Axonometric Drawing Schedules

IBS Score Calculation Conclusion

Sequence of Construction Construction Process of Model

03

References

04 05 06 07

CONTENT

01 CONCEPT & FRAMEWORK

Introduction of IBS System Types of IBS System Pros and Cons of Proposed IBS System Case Study

The IBS System INTRODUCTION Industrialized Building System (IBS) is a construction technique whereby building components are manufactured in factories then transported and assembled into a structure with limited on site work. The benefits of IBS are clear and eminent as it allows for building to be constructed in a shorter time span and with greatly reduced activities at the construction site, which in turn provides tremendous cost savings to the builders.

There are six main IBS groups identified as being popularly used in Malaysia, namely (i) Pre-cast concrete framing, panel and box systems, (ii) Steel formwork system, (iii) Steel framing system, (iv) Timber framing system, (v) Blockwork system, and (vi) Innovative system.

PRECAST CONCRETE SYSTEM

STEEL FRAMING SYSTEM

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

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

BLOCK WORK SYSTEM

STEEL FORMWORK SYSTEM

It includes of interlocking concrete masonry units (CMU) and lightweight concrete blocks. The block system is mainly used for non-structural wall as an alternative to conventional brick and plaster.

PREFABRICATED FRAMING SYSTEM

TIMBER

It consists of 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.

This IBS is made up of tunnel forms, beams and columns moulding forms, and permanent steel formworks. This system is the least prefabricated among the IBS, as it normally involves site casting. Therefore, it is subject to structural quality control, high-quality finishes and fast construction with less site labour and material requirement.

Pros & Cons

OF THE STEEL FRAMING IBS SYSTEM PROS 1) Strength & Durability Structural steel components are lighter and stronger than weight-bearing wood or concrete products. This makes steel frame construction far stronger and more durable than traditional wood framed alternatives.

2) Easy Fabrication In Different Sizes Steel studs are available in a variety of sizes and can be fabricated order. This means they can be customised to bear specific loads in buildings of all different types and sizes.

3) Fire Resistance Steel frame constructions are highly resistant to fire, reducing the fire risk to a building and retarding the spread of a fire should one occur. Special flame retardant coatings act to increase this property of structural steel.

4) Pest & Insect Resistant Structural steel components are immune to the degrading effects of burrowing insects and mammals – which can cause a problem for wooden framework unless adequately treated.

5) Moisture & Weather Resistance Structural steel can have good moisture resistant properties, depending on its carbon content. Hot zinc coating and extra powder treatments for enhanced rust resistance will make a structural steel component even more immune to the effects of water – an important consideration for components exposed to the weather.

CONS Steel frame constructions do have a couple of disadvantages, the most regularly cited being: 1) Thermal Conductivity Steel is not known for its warmth, due to its high efficiency in conducting heat. The insulation value of walls can be reduced by as much as half when heat is transferred away through steel studs, which is not good news for energy retention in a building. Where steel frame construction is used, insulation measures need to be put in place to counteract the thermal conductivity of steel.

2) Reduced Flexibility On Site One of the benefits of using wooden structural components is the ability to adjust them on site. A component can be cut down to size, nails hammered in to strengthen the join and so on. This obviously can’t happen with steel. The measurements of steel need to be precisely calculated in advance, because a steel fabrication is delivered to site in its final form, ready to be slotted into the building. This is of course one of the big advantages of steel, but if the fabrication has resulted in an inaccurate component for whatever reason, the project may be held up while the framework is sent back to the workshop for adjustment.

You can avoid this issue by working with a fabrication company such as GLW, where we take a consultative approach to accuracy and measurements from the very beginning, to avoid any unpleasant surprises on site.

3) Supporting Structures Steel frame constructions rarely work on their own. They usually require drywall, sheathing, insulation and supplementary wooden components to bring a building together. In the opinion of some construction businesses, this longer construction time is an argument against steel frame constructions, although usually the time savings outweigh any adjustments that need to be made on site.

Modern Forest City Framing Apartment

5-Storey

Light

Gauge

Steel

CASE STUDY 1

Component

IBS Factor

Analysis

Wall: In-situ Concrete with reusable system formwork

0.5

Partial IBS Factors

Structural System: Steel Column and Beam

0.9

Full IBS Factor

Table of IBS Factor *0.1 - 0.5 as Partial IBS Factors 0.6 - 1.0 as Full IBS Factors

Conventional Construction

Precast Component

Foundation

Prefab Steel Staircase

Steel Column & Beam

Wall: In-situ Concrete with reusable system formwork

Location: Xiantao, China IBS System Used: Steel Framing System Precast Concrete Precast Concrete Project Details:

Precast Concrete Slab

Modern Forest City is a high-class residence project built in China. As the sample project of green and healthy light gauge steel frame building in China, Modern Forest City presented Titan light steel integrated building system perfectly.

Precast Concrete Wall

Table Of Conventional Construction & Precast

02 IBS COMPONENTS

Cast In-situ Foundation Hollow Core Floor Slab Column & Beam Acotec Wall Panel Prefab Metal Roof Truss Prefab Concrete Staircase Toilet Pod

Foundation

Foundation & Column Connection Detail

CONSTRUCTION

System: Cast In Situ Pad Footing The strength of a building lies in its foundation. The anchor bolt transfer tension, compression and shear force to reinforced the concrete footing. The main purpose of the foundation is to hold the structure above it and keep it upright. The three most important factors are to bear the load of the building, anchor it against natural forces, such as earthquakes, and to isolate it from ground moisture. On the contrary, a poorly constructed foundation can be dangerous to the occupants and the neighbourhood.

200 x 200 mm H Column

Column & Wall Connection Detail Steel Column is secured with bolt and nut against natural forces.

250 x 250 mm Steel Base Plate

Anchor Bolts

200 x 200 mm H Column

300 x 300 mm Concrete Column Stump

200 mm Thickness Ground Slab 200 x 200 mm Ground Beam

25 mm Diameter Anchor Bolts

300 x 300 mm Concrete Column Stump

600 x 600 mm Concrete Footing

Slab

Hume Hollow Core Slab Capacities

Hume Hollow Core Slab Weight

PROPOSED IBS SYSTEM System: Precast Hollow Core Concrete Slab Precast slab of prestressed concrete typically used in the construction of floors in multi-storey apartment buildings. It is also known as voided slab, hollow core plank or simply a concrete plank.

Cut at an Edge

Rectangular Opening Round Opening

Edge End Cut Angular Cut

Slab & Beam Connection Detail

Slab & Beam Connection Precast Hollow Core Slab is layered on an 300 x 200 mm I-Beam as a support.

Precast Hollow Core Slab

In Situ Concrete Infill In Situ Concrete or grout fill along shear key joints

Gap for Screed / Structural Topping Milled Slot

Headed Shear Studs

Hollow Core Slab

Transverse Reinforcement Universal beam with pre-welded headed studs

Reinforcement Bars

Stirrups

Slab

PROPOSED IBS SYSTEM

Fabrication Slab Construction

4. Concreting Machine setting for concrete cover and panel thickness, using the concrete that according to design specifications,then conduct slump test to ensure adequate workability of concrete.

Procedure

1.

-

Preparing cast bed Base mould cleaning preparation, keep the mould clean and from debris and old mortar.

5. Curing Protect the hollow core panels with tarpaulin canvas in desired environment,to prevent rapid moisture loss and shrinkage crack.

2.

Application of Form Release Agent Form release agent used should have anti-rust properties and be relatively dry after application so that the strands will not be contaminated. It should be applied evenly over the mould surface.

6. Detensioning of Strands Conducting cube test in order to verify the strength of concrete element.

To check whether the concrete attained to the designed transfer strength.

3. Prestressing Strand Hauling and Tensioning When the form release agent has dried to a certain degree, it will not contaminate the strands. Then double check the strand size, spacing and pattern.

Carry out visual inspection of the surface finish to ensure there is no serious defect like honeycomb, dimensional changes, cracks and etc.

7. Final Inspection / Transfer to Storage Yards Carry out another inspection before transfer to storage yard.

Slab

PROPOSED IBS SYSTEM

Installation on Site Procedure

1.

-

2.

Inspection of Production Items on Construction Site All products of the company are marked by a special label meeting standard requirements

Unloading, Hoisting Unloading and hoisting of HCS slabs shall be conducted using a special lifting devices - a hoisting traverse, which consists of a lifting beam with two hoisting grippers.

The position of the hoisting grippers on the lifting beam shall be adapted to the length of the slab.

3. Interim Storage Interim storage on the construction site usually is not required, as production items are installed directly from a lorry. If interim storage is conducted, for this purpose a horizontally leveled site should be prepared.

5. Adjustment, Curvature Equalization Different curvatures of adjacent slabs may occur because of many influences as follows: improper storage of slabs and transportation, different length adjacent slabs. If these mismatches in the lower side of the floor exceed the allowable size - 8mm, the curvature of slabs should be necessary equalized.

6. Positioning, Installation of Ties The quantity of slab ties and their installation methods are indicated in each project. As this influence is determined by great many of different factors, in the Project, tie installation nodes, their locations on the floor and concreting peculiarities shall be indicated. More frequently, the ties are installed at the ends of slabs by the supporting members. If a floor functions as a diaphragm, the ties (anchors) shall be also installed with the longitudinal walls. For this purpose, at the sides of a floor slab, the grooves are designed.

7.

Concreting of Junctions and Joints -

4. Installation HCS are installed on a leveling neoprene strip, fastened to the bearing structure. Prior to installation the slabs on wall slabs, the smoothness of the bearing surface should be checked. If the bearing surface is not smooth, the roughness should be removed or leveled.

The installation joints that are between the slabs and also the ends of slabs should be filled with fine aggregate concrete, the strength class of which when compressing shall be C20 (Mpa), still C25, C30 (Mpa) are recommended. The maximum diameter of fillers being used shall be 8mm. The concrete shall be compacted using an internal vibrator (head diameter 20 mm).

Column & Beam PROPOSED IBS SYSTEM

System: Steel Column & Beam Column and beam steel frame structures have a skeleton of steel connected by bolts or welds that act as the support for the rest of the building. A column and beam frame can be braced or continuous. A braced frame has a web of smaller members acting to stabilize and provide rigidity to the frame, which is generally a simple pin connection. Bracing is added horizontally or vertically to the main frame, often in shaped patterns to facilitate transferring load stresses. Various prefabricated beam sections are available to be used in the construction multi storey steel frame structure. Beams commonly transfer loads from floors and roof to the columns.There are various sizes of steel column section to choose and these steel columns are commonly produced in advance. The most significant point in column installation is the connection between foundation and column and splices between columns.The reason for using steel column and beam in our apartment design, production of structural steel beams means minimum waste during construction, which is advantageous for cost saving. Moreover, steel can be fire proofed by using specialty coatings which inhibit steel deterioration in case of fire. (Seow, 2018)

Column & Beam Connection Detail

Installation On Site

Steel Column

1. Clean the site for bringing the steel structure

Nut Steel Plates Bracket Bolt

2. Erection of Steel Column and Steel Beams

Steel Beam

3. Connect the steel structure by bolt, welds, pins and rivets

Steel Plates Bracket, or tee connect web of beam to side of column.

Beam assembly is bolted to the column in the field.

4. Installation precast wall and floor to beams

5. Fastening the connection

Column & Beam

3. Punching and drilling These can drill many holes in flanges and webs of rolled steel sections simultaneously.

It is also possible to punch holes, and this is particularly useful where square holes are specified such as anchor plates for foundation bolts.

PROPOSED IBS SYSTEM

Fabrication of Column Construction Procedure

1. Surface Cleaning Structural sections from the rolling mills may require surface cleaning to remove mill scale prior to fabrication and painting.

4. Straightening, bending and rolling Rolled steel may get distorted after rolling due to cooling process. Further during transportation and handling operations, materials may bend or may even undergo distortion. This may also occur during punching operation. Therefore before attempting further fabrication the material should be straightened.

5. Fitting and Reaming Before final assembly, the component parts of a member are fitted-up temporarily with rivets, bolts or small amount of welds. The fitting-up operation includes attachment of previously omitted splice plates and other fittings and the correction of minor defects found by the inspector.

i) Blast cleaning

ii) Flame cleaning

2. Cutting and Machining - Following surface preparation, cutting to length is always the first process to be carried out, and this is done by any of the following methods.

6. Fastening (Bolting, Riveting and Welding) The strength of the entire structure depends upon the proper use of fastening methods.

Welding is the most common method of shop fabrication of steel structures.

7. Finishing Structural members whose ends must transmit loads by bearing against one another are usually finished to a smooth even surface. Finishing is performed by sawing, milling or other suitable means.

8. Quality Control 9. Surface treatment Structural steelwork is protected against corrosion by applying metal or paint coating in the shop or at site.

i) Shearing and Cropping

ii) Flame Cutting or Burning

i) Metal Coatings iii) Arc Plasma Cutting

iv) Cold Sawing

10. Transportation

ii) Paint Coatings

Beam

PROPOSED IBS SYSTEM

Fabrication of Beam Construction Procedure

Limestone + Ore

Coal

Reheating Furnace

Pigiron

Roughing Mill

Intermediate Rolling Mill

Finishing Mill

Cutting

Blast Furnace Cooling Bed

Roller Straightener

Products

Continuous Caster

Basic Oxygen Vacuum Degassing Furnace Equipment Conventional Flange Beam

Universal Rolling

Roughing

Reheating Furnace

Roughing Mill

Intermediate Rolling Mill

Finishing Mill

Cooling Bed

Roller Straightener

Camber Inspection

Intermediate Rolling

Finish Rolling

Automatic Warehouse

Walls

Acotec Wall Installation Instruction

PROPOSED IBS SYSTEM System: Precast Concrete Wall (Acotec Wall Panel) Acotec Wall Panel is an idea developed to facilitate a hassle-free building process of Industrial Building System. The Acotec Wall Panels are quick and easy to install, no plastering is needed at the construction site.

1. Upper Edge Gap: 5-15 mm Wooden wedges at the upper edge Fixation: Acrylic paste / angle iron Tilefix with paper strip in wet sanitary facilities Tilefix / fireproof urethane in fire compartmentation walls

3. Lower Edge Gap: 20 - 40 mm Urethane pieces in between Fixation: Mortar

Advantages of Acotec Partition Wall 1.

2.

3.

4.

5.

6.

7.

2. Panel Seams Gap: Maximum 2 mm Fixation: Tilefix Sealing: Paper strip

Speed of Construction Time Efficiency Low Wastages Industrial Quality Finishes Easy Site Management Lower Pilferage Environmental Friendly

4. Exterior Wall Gap: 2 mm Fixation: Elastic putty Tilefix in fire compartmentation and wet sanitary facility walls

5. Door Opening Implemented with Flat Bar Iron With milled slots for flat bar irons in the adjacent panels Fixation: Tilefix Sealing: Urethane

Comparison of Acotec with Brick and Block Wall Partition

1. Angle at the Connection of Two Panels Filling the hollow cavities of a cut panel with mortar Nail anchors with one-metre spacing Steel fitting in the ceiling at a distance of more than three metres

Block 3m2/h

Brick 1m2/h Acotec 6m2/h

DImension of Acotec Partition Wall One unit of 600mm x 3000mm panel (75mm & 100mm thickness) is equivalent to 112 pieces of bricks.

2. Panels Surface Finishing 1-3 mm filling: Thin skim coating In sanitary facilities, the skim coating needs to be water-sealed

3. Door Opening Implemented with Grooves Adjacent panels are milled Fixation: Tilefix Sealing: Urethane

Walls

PROPOSED IBS SYSTEM

Fabrication of Wall Procedure

4. Trimming When necessary, the fresh product is topped at a specified point, where the manually adjusted circular saw cuts off the wanted trimming piece. Trimming length is max 20cm. The trimmed�off concrete is then recycled back to the extruder.

5. Stacking Cut, fresh products are stacked into precuring stacks.

Depending on the product thickness and weight, each stack contains 4 to 10 products and base molds. Stacks are supported by steel pallets, which are automatically fed underneath each stack. Then the stacks are moved to the ocuring area either by an automated conveyor system, by a forklift or by a crane.

1.

Concrete Supply The concrete required is batched and mixed at an automatic batching and mixing station. The relatively dry aggregates are automatically batched into the mixer and added with water. Moisture content of the mixed concrete must be automatically controlled and adjusted. After mixing, the concrete batch is fed to the conveying system, which brings fresh concrete to the line’s hopper.

2.

-

Extruding The Acotec-wall elements are formed in a continuously operating extruder. The concrete is compacted onto thin base molds which then automatically fed to the extruder as a continuous ribbon. The extruder compacts the concrete with extrusion screws against the packing bar and sidewalls. The top surface of the product is vibrated by a vibrating plate.

3. Cutting After extruding, the products are cut according to the base mold length. A circular saw cuts the fresh concrete on each base mold seam. Them the cut product together with the supporting plate is pulled to the stacker.

6. Procuring The stacks must stay in the procuring storage area, which is, where natural curing (temperature should be above +10° C) occurs for 15 to 24 hours. In a dry climate, the stacks should be covered with tarpaulins. The product stacks are moved in and out of the storage area with a forklift, a crane or automatic conveyor lines.

7. Restacking After procuring has taken place, the products are strong enough to withstand automatic handling which then separated from the base molds, which are put back into circulation after passing through a cleaning and oiling unit.

The products are restacked to form delivery stacks and is pushed against a wooden delivery pallet and turned on its side.

8. Packing Delivery stacks are strapped and preferable wrapped before transportation to delivery storage. Stacks must stay in delivery storage for at least 14 days before being transported to a construction site.

Walls

PROPOSED IBS SYSTEM

According to manufacturer instructions, gluing agents should be mixed carefully using the recommended safety equipment.

Installation On Site Procedure

A maximum of two stacks can be placed on top of each other during storage and transportation. The stockyard should be level and panels should be protected from the rain.

The panels must be stored on their sides at all times.

The line that the wall will follow is marked to the floor and ceiling before starting the installation.

All steps or raised platforms must conform to local regulations.

A lifting fork or belt should be placed under the wooden pallet to lift panel stacks.

The capacity is to be checked against load being allet to lift panel stacks.

Guiding boards are placed on the floor and ceiling and wedged into place using timber stringers.

The guiding support will automatically align the wall when lifting the panels.

Acotec Panel stacks can easily be moved at the construction site by a forklift or a trolley. Due to the weight of the load to be transported, powered equipment may be required in addition to adequate manpower, depending on load size.

The joint is filled with polyurethane foam (alternatively with mineral wool or foamed plastic), and paper tape glued to the corners before skimming.

Individual Acotec Panel can easily be moved by the turning barrow trolley.

The amount of manpower required depends on the panel size.

The gluing agent is applied to the side of the already installed Acotec Panel.

According to manufacturer instructions, gluing agents should be mixed carefully using the recommended safety equipment.

Acotec Panel is positioned at the correct level by using plastic shims on the floor and kept in place by using wooden wedges at top of the Acotec Panel.

The gap between the panel and the ceiling is filled with polyurethane foam using a stepladder of up to 3 steps or a platform.

The excess glue is removed from joints immediately after installation. Wedges are removed after panel adhesive is cured.

The gluing agent is applied to the side of the already installed Acotec Panel.

Walls

PROPOSED IBS SYSTEM Before plastering, paper tape should be glued over the corner joints.

Installation On Site Procedure

Sawing and drilling of an Acotec Panel are easy. Use the tool manufacturer's safety equipment and the correct P.P.E.

Also, before plastering, paper tape should be glued to the joints above the door.

The panels next to the door, 'shoulders' are sawed for the door top piece. The door top piece is glued using polyurethane foam or gluing agents.

The hollow cores allow cables to be pulled through, electrical boxes can be drilled to any desired point.

Flexible joints between Acotec Panel should be used every 4,8 – 6m. Polyurethane foam or mineral wool can be used as elastic joint material.

All corners should be strengthened with nail plugs. (3 plugs per corner).

Acotec Panel Wall needs a very thin plaster skim of (1 – 3mm) before surface finishing. This can be applied using a long trowel. Skim coating can be applied after 2 weeks in normal lifting fork or belt should be placed under the wooden dry conditions.

Staircase

Precast Concrete Staircase Connection Details

PROPOSED IBS SYSTEM

System: Precast Concrete Staircase

Precast Staircase risers

Landing Slab

Dowels drilled on to foundation

Ground floor slab

Precast Staircase to landing slab connection

Precast concrete staircase to ground floor slab connection

300mm thick Precast landing with 75mm thick concrete screed

75mm thick concrete screed Precast Staircase risers

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

Installation On Site 1.

2.

Steel brackets are bolted to the foundation using concrete anchors. These will be used to catch the legs at the back of the stairs

Small concrete pads are set under each side of the steps toward the front of the unit. These pads are set slightly lower than the brackets so that the stairs are pitched forward for water run off.

Advantages 1.

Smooth surface finish.

2.

Eliminates the need for temporary stairs during construction.

3.

Safety rails and handrail can be pre-installed prior to installation.

4.

Better quality control.

5.

Positioned and fixed by semiskilled labour.

6.

Speed & Ease of installation

7.

Money saving solution. Cuts construction time, eliminates need for temporary stairs.

3.

The precast stairs are then set on the brackets and pads using a boom truck. Solid steel shims are used to make small adjustments if necessary.

8.

Excellent fire resistance.

9.

Flexibility of design.

Roof Truss

Installation On Site

PROPOSED IBS SYSTEM

System: Prefabricated Gable Steel Roof Truss Prefabricated steel trusses offer a high strength, lightweight roof system that can be installed quickly and recyclable, lt allow greater spans in the structure. Although the cost is higher compare to wood trusses, it has higher durability and flexibility which only require little maintenance.

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

Advantages Better Quality Higher quality materials and strength; roof trusses are fabricated inside a shop, where the materials are not exposed to inclement weather or moisture conditions.

Fast Trusses can typically be installed in a single day, speeding the home construction process and getting the structure closed up sooner, which helps prevent moisture and other weather elements from getting inside.

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

Long Span Roof trusses can span much longer distances without the need for load bearing interior walls.

Roof Truss to Beam Connection 3.Trusses are lifted by a crane and is aligned into position and which is then bolted into place.

Bottom Cord of Truss Internal Wall Bracket

Steel H Column

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

Roof Truss PROPOSED IBS SYSTEM

Fabrication of Prefabricated Roof Construction Procedure

4. Pressing 1. Design Design in place for the truss before the building process can start. Calculation of size and dimensions, Then create a truss that meets the requirements of the client and of local building codes.

The last step in manufacturing a roof truss is pressing. Here, with all of the metal cut and the truss plates put into their appropriate place, the whole assembly goes through a hydraulic press and receives a final inspection.

Upon completion of the inspection, the truss is done and ready to be shipped out to the building site.

5. Assembly 2. Creating a Template To conduct a efficient manufacturing process, the manufacturer creates a template to outline exactly which pieces need to be used in which locations, how they will all fit together and where they will need to place plates.

3. Cutting Cut the C-channel pieces out that are going to be used to build the trusses. All pieces should be cut accurately in order to meet the building specifications when complete.

After all of the pieces for the trusses are collected, the cut pieces of metal are inserted into the template created to make manufacturing more efficient. This ensures they match the design that has already been put in place. After this, the truss manufacturer puts the truss plates into place and prepares for the final step.

Bathroom Pod PROPOSED IBS SYSTEM

The size and shape enable easy manufacturing, delivery and installation. It recommends that the internal bathroom dimensions are not greater than 2.3 meter wide by 3.0 meter long internally. The bathroom pods contribute to a cleaner and safer work environment, help reduce labor, materials, waste, and costs, and increase speed to occupancy,

Fabrication Toilet Pod Construction Stage One: Production All construction for the bathroom pod is done off site where a large number of pods are mass-produced in a controlled factory environment Stage Two: Storage and Transportation

Cold formed steel framing, designed, engineering and manufactured by MMSL.

Stage Three: Installation

The finished modules are delivered by truck to site based on the project timeline.

Bathroom pods are removed from the truck using specialised moving equipment.

Bathroom pods are removed from the truck using and hoisted into the building.

Backing plate installed for solid connections of shower heads, grab bars and any wall mounted fixtures.

Moisture resistant products used throughout pod construction.

Modular wiring included for interior pod fixtures and exterior pod applications i.e. light switches, receptacles, thermostat.

Low profile floor including waterproofing agents applied prior to finish materials.

Once each pod has been constructed it is stored in a warehouse where the pod in ready to be immediately transported onto site on request by the client. The pod is transported by lorry to site together with the other items required to construct the rest of the apartment rooms, these are transported separately on another lorry

Installation On Site

Totally finished interior.

Ready to use for arrival.

TheModularBuildingInstitute, 2018

Site based cranes are used to hoist the bathrooms into the building structure.

Wrapped bathroom pods quickly fills in the open bay.

Bathroom are in the building structure prior to the interior facade going up.

Mechanical and partition wall has been installed and it’s time to slide the bathroom pod into it’s final location.

The bathroom is now located in its final and ready for MEP connections.

Above the bathroom, it is framed to the ceiling to integrate the pod fully within the room.

The exterior of the bathroom pod receives the same finish as the rest of the room and blends seamlessly.

The bathroom pod is now part of the room and blends in as if it were built in place

03 SEQUENCE OF CONSTRUCTION Construction Process of Model

Construction Process of Model SEQUENCE OF CONSTRUCTION

1. Foundation

2. Ground Beam

3. Column & Beams

3. Roof

Foundation is cast on site on the excavated terrain.

Ground Beam are placed on top of concrete footings accordingly.

Steel Column & Beams are then installed on top of the of the column stump.

Prefabricated Steel Truss are installed.

5. Slab Slab is then cast on the top of ground beam and followed by internal walls

04 TECHNICAL DRAWINGS

Architectural Floor Plan Roof Plan Elevations Section A-A’ Section B-B’ Foundation Plan Structural Plan Structural Section Axonometric Drawing Schedules

Acotec Internal Wall Panel Precast External Wall Panel Insulation Elastic Putty

Shear Connection End Plate Section Callout 1:25 Wall System

20mm Bolt

Floor Treatment

Screed (Sand & Cement) Reinforcement Bar Hollow Core Slab Mortar Section Callout 1:25 Floor System

25mm Thick Metal Deck Roof

Vapour Sheeting

18mm Thick Plywood

Section Callout 1:25 Roof System

25mm Thick Fascia Board

Slab

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Slab 1

Slab 2

Slab 3

Slab 4

Slab 5

System

Precast Hollow Core Slab

Precast Hollow Core Slab

Precast Hollow Core Slab

Precast Hollow Core Slab

Precast Hollow Core Slab

Quantity

6

6

6

54

6

Slab, Beam & Column SCHEDULE OF IBS COMPONENT

Elevation View (Length)

Section View (Height & Width) / Perspective View (Thickness)

Component

Slab 6

Beam 1

Beam 2

Column 1

System

Precast Hollow Core Slab

I-Beam

I-Beam

H-Column

Quantity

6

116

8

24

Wall

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Wall 1

Wall 2

Wall 3

Wall 4

Wall 5

System

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Quantity

3

6

6

6

6

Wall

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Wall 6

Wall 7

Wall 8

Wall 9

Wall 10

System

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Quantity

6

6

3

6

12

Wall

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Wall 11

Wall 12

Wall 13

Wall 14

Wall 15

System

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Quantity

3

3

3

3

3

Wall

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Wall 16

Wall 17

Wall 18

Wall 19

Wall 20

System

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Quantity

3

3

3

3

3

Wall

SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height)

Perspective View (Thickness)

Component

Wall 21

Wall 22

Wall 23

Wall 24

Wall 25

System

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Precast Concrete Wall

Quantity

6

3

6

6

6

Door, Window & Staircase SCHEDULE OF IBS COMPONENT

Elevation View (Length & Height) / Perspective View (Thickness & Width)

Plan View (Width)

Component

Door 1

Door 2

Window 1

Staircase

System

Door

Door

Window

Staircase

Quantity

48

12

42

3

05 IBS SCORE

Calculation

IBS Score CALCULATION

Area (m2) Or Length (m)

IBS Factor

Coverage

IBS Score

Prefabricated Steel Roof Truss

303.75m2

1.0

303.75 1215.00 =0.25

50∑{[0.25][1.0]} =12.5

Steel Column & Beam with Precast Concrete Slab 303.75 x 3 Storeys =911.25

911.25m2

1.0

911.25 1215.00 =0.75

50∑{[0.75][1.0]} =37.5

1215

-

1

50/50

270m

1.0

270.00 524.55 =0.51

20∑{[0.51][1.0]} =10.2

254.55m

1.0

254.55 524.55 =0.49

20∑{[0.49][1.0]} =9.8

524.55

-

1

20/20

Elements

Part 1: Structural System

Total Part 1

Part 2: Wall System External Wall : Precast Concrete Panel Total length = 90m x 3 storeys = 270

Internal Wall : ACOTEC (Precast Concrete Panel) Total Length : 84.85m x 3 Storeys = 254.55m

Total Part 2

IBS Score CALCULATION

Elements

Area (m2)

IBS Factor

Coverage

IBS Score

PART 3: Other Simplified Construction Method Utilisation of Standardised Components Based on MS 1064 i) Steel Column

100%

4

ii) Steel Beam

100%

4

iii) Wall

0

0

iv) Slab

0

0

v) Door

0

0

vi) Window

0

0

Horizontal Repetition of Structural =100%

100%

2

Vertical Repetition of Structural Floor Layout = 100%

100%

2

Repetition of Floor to Floor Height = 100%

100%

2

Structural Layout

Total Part 3 IBS Contents Score of Projects (Part 1, Part 2 and Part 3)

` Part 1 + Part 2 + Part 3 =50 + 20 + 14

14 84 / 100

05 CONCLUSION

IBS SYSTEM

Conclusion IBS SYSTEM

The IBS is an ideal building system that will promote environmental sustainability, resulting in less wastage of materials, compared to conventional construction methods.

It is also the construction method of choice in enhancing worker safety and working conditions by reducing accidents and fatalities at work sites.

IBS has many advantages that leads to the efficiency of erecting a building. Besides, IBS systems such as steel frame structure and steel framework system are beneficial due to it’s lightweight properties and flexibility which allows the fabrication process to be conducted fast and easy. For example, steel framing systems are long-lasting and recyclable. Although there are limitations due to material properties, however several treatment methods can help solve this issue.

This assignment has allowed us to have a clearer and deeper understanding towards what an IBS system is. Also, by proposing a certain IBS system proposal on our apartment building, it has cultivated an in depth knowledge on the proposed IBS system, which is the steel framing system and steel framework system. Besides, with the construction of a physical model. We are able to get a grasp on the prefabrication process and the ‘on-site’ assembling of the model which resembles the actual site construction itself. This has also allows us further understand on how each components are joined up and connected to one and another.

Hence, with the use of the IBS score calculation, a systematic and structured assessment allows us to identify whether our apartment building fulfils the IBS score benchmark. With the usage of standard dimensions and fulfilling the requirements as stated in MS1064. Our building has achieved a total IBS score of 84/100.Thereby it is shown that this building has achieved the following attributes which emphasises on the usage of prefabricated precast components, off-site components, the use of standardised components, repeatability and is designed using a modular-coordination concept.

06 REFERENCES

References APA STYLE

ACOTEC WALL PANEL. (2010). Retrieved from http://www.acotec.com.my/main.php ACOTEC. Acotec panel production D /EN/E 1(14) PROCESS DESCRIPTION ACOTEC PANEL PRODUCTION - PDF. (2012). Retrieved from https://businessdocbox.com/Construction/68687623-Acotec-acotec-panel-production-d-en-e-1-14-process-description-acotec-panel-production.html (2015). Retrieved from https://www.bca.gov.sg/Publications/BuildabilitySeries/others/bswall.pdf Bathroom Pod Installation On Site | Oldcastle SurePods. (2012). Retrieved from https://oldcastlesurepods.com/factory-built-bathrooms/on-site/ Connector Hollow Core Slab on STEEL STRUCTURE. (2013). Retrieved from https://www.youtube.com/watch?v=Ryoiu4rO8X8 Hollowcore | Concrete | Longley Group | Concrete Products | UK | London | Yorkshire. (2013). Retrieved from https://www.longley.uk.com/products/hollowcore/ Ibs Complete | Precast Concrete | Framing (Construction). (2010). Retrieved from https://www.scribd.com/doc/21794505/Ibs-Complete Manufacturing Process | Structural steel | Products | Nippon Steel & Sumitomo Metal Corporation. (2014). Retrieved from https://www.nssmc.com/en/product/construction/process/ Methods of Installation for Steel Structure | Column | Precast Concrete. (2016). Retrieved from https://www.scribd.com/document/248472778/Methods-of-Installation-for-Steel-Structure This is how to install the Acotec partition wall panel correctly. (2014). Retrieved from https://www.concreteissues.com/en/stories/1-16/this-is-how-to-install-the-acotec-partition-wall-panel-correctly/ White, G. (2012). The Advantages & Disadvantages Of Steel Frame Construction. Retrieved from https://blog.glwengineering.co.uk/the-advantages-disadvantages-of-steel-frame-construction