PROJECT 1: INDUSTRALISED BUILDING SYSTEM

BUILDING TECHNOLOGY I (BLD61403)

INDUSTRIALIZED BUILDING SYSTEM (IBS) TUTOR: AR. EDWIN CHAN MEMBERS: CLARA LEE PEI LIN JOY ANN LIM EE HSIEN LIM ZHAO YIN TAN WEI SEN WONG TECK POH

0324495 0327592 0329356 0324564 0327462

01

CONCEPT AND FRAMEWORK

Introduction Types of IBS IBS Standard Workflow Proposed IBS Case Study

03 04 06 07 09

02

PROPOSED IBS COMPONENTS

Foundation Columns Beams Slab Wall Roof Staircase Toilet Pod

12 13 15 17 21 24 26 28

SEQUENCE OF CONSTRUCTION

Construction On Site 30 Construction of Scaled Model 37

TECHNICAL DRAWINGS

Orthographic Drawing and Specification Schedules

39

IBS SCORE CALCULATION

IBS Score Calculation

57

CONCLUSION

Conclusion

60

REFERENCES

References

62

03 04 05 06 07

CONTENTS

01

CONCEPT & FRAMEWORK Introduction of IBS Types of IBS IBS Standard Workflow Proposed System of IBS Case Study

01

INTRODUCTION

03

INDUSTRIALISED BUILDING SYSTEM (IBS)

An Industrialised Building System (IBS), also known as prefabrication, refers to a technique of construction whereby components are manufactured in a controlled environment - either onsite or offsite - placed and assembled into construction works with little additional site work.

IBS solutions have been adopted in Malaysia since the 1960’s to reduce the house shortage to accommodate the Malaysian population boom. However, the Malaysian construction industry only began to utilise IBS in the 1990’s, where prefabricated components are used in many national iconic landmarks such as Kuala Lumpur Convention Center and Bukit Jalil Sports Complex as well as construction of private and high rise residential buildings (CIDB, 2006).

Over the years, the new generation of building that utilised IBS has proven to be better than the conventional methods in term of lower construction cost, faster completion time, higher quality of components and better architectural appearance.

• • • • • • • •

High quality control and aesthetic value Cost saving in the long run Reduction in labour and unskilled workers Reduction in construction time Provide a safer and cleaner working environment Reduction of waste materials Construction operation is not affected by weather conditions Systematic operation which increases consistency of materials

DISADVANTAGES OF IBS • • • •

Higher initial cost for specialised machinery to cast components High transportation cost Requires highly skilled workers Inflexible prefabricated structures as its form cannot be changed

CONCEPT & FRAMEWORK

ADVANTAGES OF IBS

01

04

TYPES OF IBS Precast wall panels

Precast Concrete System

Precast concrete system is the group that is most widely used in the IBS. It includes precast concrete columns, beams, slabs, walls, “3-D� components (e.g.: balconies, staircases, toilets, lift chambers, refuse chambers), lightweight precast concrete, as well as permanent concrete formworks.

Precast concrete column and beam Precast hollow core slab Steel portal frames

Steel Framing System

CONCEPT & FRAMEWORK

This system includes steel trusses, beams and a column portal frame system. It is frequently used with pre-cast concrete slabs, steel beams and columns as well as portal frame systems. It is always preferred and widely used in the constructions of skyscrapers and also in the constructions of large factories and exhibition halls that require wide areas.

Steel beams and columns Steel roof trusses Tunnel formwork

Formwork System

Identified as one of the least prefabricated types of the IBS, it generally involves concrete at the construction site and high quality control. These products provide a high quality finish, faster construction and demand relatively less labour and materials. The formwork system includes tunnel forms, tilt up systems, beams and columns moulding forms, and permanent steel formwork.

01

Steel formwork Insulated concrete formwork

05

TYPES OF IBS Prefabricated Timber Framing System

This system involves prefabricated timber truss beams and columns. Most of the products listed in this category are wooden building frames and roof trusses. It is quite popular and widely applicable as it provides attractive designs and high aesthetic values as chalets for resorts, contributing very much to the tourism industry

Prefabricated timber beams and columns Prefabricated timber roof trusses

01 CONCEPT & FRAMEWORK

Blockwork System

Blockwork system consists of interlocking concrete masonry units (CMU) and lightweight concrete blocks. They have a hollow core that makes them easier and lighter to work with as well as insulation properties. Blockwork has become a popular alternative to clay bricks and is often used to build partition walls and retaining walls.

Concrete masonary units Load bearing walls

06

IBS STANDARD WORK FLOW

01 PRODUCTION PHASE

TRANSPORTATION PHASE

The industrialised building system (IBS) begins with the design phase, where a structure is designed with the intent of increasing productivity and quality at construction sites.

IBS has to comply to MS (Malaysian Standard) 1064 which is the guide to modular coordination in buildings.

Once the design phase has been completed, the production phase begins.

IBS components are manufactured off-site according to the specific dimensions and details in quality-controlled factories.

After a certain quota is reached, completed IBS components are transported to the construction site for assembly.

1

2

3

ASSEMBLY PHASE The assembly phase is executed using specialised machineries to aid the building erection process.

This phase requires coordination to prevent wastage and inefficiency on site.

4

CONCEPT & FRAMEWORK

DESIGN PHASE

07

PROPOSED IBS Proposed IBS of a 3-storey apartment building: Steel Framing System

The proposed IBS is a steel framing system combined with precast concrete system. A steel framing system allows for a building that is strong but low in weight with an increased speed of construction. Steel structures are able to span for a longer distance at a lower cost compared to other IBS. Steel framing system involves several types of construction and installation methods. A conventional steel construction requires fabrication of steel components off-site and they are joined together by welding on site.

These steel components can also be bolted together. Light gauge steel members are another method of steel construction where the system is similar to a timber framework system where timber studs are replaced by steel members.

Conventional steel construction bolted together on site

CONCEPT & FRAMEWORK

Steel framing system is usually paired with precast concrete system such as precast concrete panels and floor slabs. Since precast is manufactured in a controlled environment, the precast structures are easily quality controlled and therefore the construction cost can be reduced.

01

Light gauge steel construction

Steel framing and precast concrete system

08

PROPOSED IBS Proposed IBS of a 3-storey apartment building: Steel Framing System

COMPONENTS OF THE PROPOSED APARTMENT

PRECAST CONCRETE

CAST IN-SITU

Ground beam Beam Column Roof truss

Hollow core slab Wall Staircase

Foundation Ground slab

ADDITIONAL

ADVANTAGES OF STEEL FRAMING SYSTEM

DISADVANTAGES OF STEEL FRAMING SYSTEM

• • • • • •

• • • •

High strength to weight ratio compared to concrete High durability Easy fabrication with different sizes Variety in joint connections Recyclable Pest and insect resistant

High thermal conductivity Susceptibility to buckling Fireproofing cost Maintenance cost due to high susceptibility to corrosion

Toilet pod

01 CONCEPT & FRAMEWORK

PREFABRICATED STEEL

09

CASE STUDY STEEL FRAMING SYSTEM

PETRONAS RAPID PROJECT PACKAGE 1

Building Function : Temporary Camp Facilities (Admin office, warehouse, mess hall, shelter etc),

Petronas Refinery and Petrochemical Integrated Development (RAPID) Project.

Location : Pengerang, Johor Date of Completion : August 2015 Owner : PETRONAS Consulting Engineer & Contractor : CTCI Engineering & Construction Sdn. Bhd. Manufacturer : AME Engineering IBS : Steel Framing System

01

1 The steel constructed

2 structure

is

The prefabricated floor slabs are placed

3 Prefabricated steel roof is installed

4 Interior prefabricated concrete wall is placed

5 Exterior prefabricated steel cladded wall is placed

CONCEPT & FRAMEWORK

Temporary Camp Facilities (Admin office, warehouse, mess hall, shelter etc), Petronas Refinery and Petrochemical Integrated Development (RAPID) Project.

Procurement, construction and commissioning of three blocks of Supervisor’s Dormitory (120 persons per block) and two blocks of Manager’s Dormitory (60 persons per block) for P1 Camp, Pengerang RAPID Project. The scope of works inclusive of steel structures, civil work, roofing & wall cladding, internal partition wall, solid panel wall, ceiling, flooring, sanitary & plumbing, electrical and fire fighting system.

10

CASE STUDY STEEL FRAMING SYSTEM

TABLE OF IBS FACTORS IBS Factor

Analysis

Wall: precast concrete panels (interior)

1.0

Full IBS factors

Wall: Wall cladding (exterior)

1.0

Full IBS factors

Structural System: Steel Column and Beam

1.0

Full IBS factors

TABLE OF CONVENTIONAL CONSTRUCTION AND PRECAST COMPONENTS Conventional Construction

Precast Components

Foundation

Prefabricated concrete staircase Prefabricated roof panels Prefabricated concrete wall panels Prefabricated concrete slab Prefabricated steel wall panels

01 CONCEPT & FRAMEWORK

Components

02

PROPOSED IBS COMPONENTS Foundation Columns Beams Slab Wall Roof Staircase Toilet Pod

02

12

FOUNDATION ADVANTAGES OF CONCRETE PAD FOUNDATION: Foundations carry and spread concentrated loads to the soil from superstructures. They are usually placed to transfer point loads from the column or framed structures and consists of a concrete block or concrete pad.

The proposed apartment uses a concrete cast in-situ pad footing. The pads are usually placed at a shallow depth, but they can also be used as deep foundation depending on the loads to be transferred and condition of the subsoil.

CONNECTION DETAILS:

Concrete pad footing

Steel column to concrete foundation connection detail

02 Steel column

Nut

Holding down bolt

500 x 500mm base plate

Cast in-situ concrete footing

Sectional detail

Non shrink grout

PROPOSED IBS COMPONENTS

Pad foundations may be square, rectangular or circular in shape. The loads from the structure are simply distributed by the pad to the bearing layer of soil. Pad foundations are also used to support ground beams. The type of foundation is determined by the soil bearing capacity.

• Economic • Shallow pad foundation requires less excavation • Size and shape can be varied depending on site condition

13

COLUMN ADVANTAGES OF STEEL COLUMN: Steel columns are structural members designed primarily to support axial compressive loads applied to the ends of the members. It acts as a compression member transferring its weight and the weight of the structure above to other structural members below.

• • • • • •

High durability Less columns with longer spans needed due to high strength to weight ratio Slenderness of material gives an aesthetic appeal Can be recycled Faster period of construction Fire resistant through fireproofing

PRODUCTION PROCESS (STEEL COLUMNS & BEAMS): Steel H column

The proposed steel framing system for the apartment uses steel H columns.

02

Heating and Molding The steel is heated in a rotary hearth heating furnace.

4 Punching and Drilling A machine is used to form holes in the beam for connections

5 Bolting, Riveting, Welding Before final assembly, the component parts are fitted-up temporarily with rivets, bolts or small amount of welds.

2 Cutting The steel is cut to length or width by cropping or shearing using hydraulic shears

6 Finishing Finishing is performed by sawing, milling to get a smooth even surface.

3 Straightening and Rolling The shape is formed by rolling using caliber rolls. The product is finished by a universal mill and an edging mill.

7 Surface Treatment The columns/beams need to be treated to prevent corrosion by applying metal or paint coating

PROPOSED IBS COMPONENTS

1

14

COLUMN CONNECTION DETAILS Steel column connection detail

to

column

Bolted Cover Plate Column Splices Column splices in multi-storey construction are required to provide strength and continuity of stiffness about both axes of the columns.

Splices are typically provided every two or three storeys and are usually located approximately 600mm above floor level. The connection uses external cover plates bolted to unite the flanges of the two steel columns of similar depth.

Steel H columns

02 PROPOSED IBS COMPONENTS

Bolts

Packs

Sectional detail Cover Plate

15

BEAMS ADVANTAGES OF STEEL I BEAM: Steel beams are structural products made to support heavy loads. It comes in varied types and sizes such as I beams, C channels and T-beams.

The proposed steel framing system for the apartment uses steel I beams. The shape of the I beam allows the horizontal flanges resist the bending movement, while the web resists the shear stress.

• • • • •

High strength to weight ratio Can withstand extensive deformation without failure under high tensile stresses Versatile in terms of function due to the shape Cost effective and minimal waste Can be rolled or cut and turned into a variety of sizes and shapes without changing its composition or physical property • Fire resistant through fireproofing

CONNECTION DETAILS

Steel I beam

Steel beam to beam connection detail - End Plate Connections

The end plate may be partial depth or full depth. It is welded to the supported beam in the workshop then bolted to the supporting beam or column on site. The choice of an using an end plate is relatively inexpensive and is stronger then using a double angle web cleat connection but may have less opportunity for site adjustment.

PROPOSED IBS COMPONENTS

Double notched flange

Welded end plate

Bolts

Supporting I beam

02

Sectional detail If beams are of similar sizes both flanges are notched. to allow it to fit to the web of the supporting beam.

COLUMN & BEAMS

16 End Plate Connections Similar to the connections of the beam to beam, the steel beam and columns are connected and assembled by using an end plate connection.The plate is welded on to the end of the beam and bolted on site when aligned to the accurate position.

CONNECTION DETAILS

Steel column to steel beam connection detail Steel H column

02 PROPOSED IBS COMPONENTS

Welded end plate

Bolts

Sectional detail

Steel I beam

SLAB The proposed apartment uses precast hollow core slab.

A hollow core slab, also known as a voided slab are prestressed concrete elements that have a constant cross section. They are manufactured using high tensile strength prestressed strands or single wire which are embedded within the element.

ADVANTAGES OF HOLLOW CORE SLAB: • • • • • • •

Quick and easy installation with minimal labour force needed Long span without need of temporary supports High durability and load resistance Can be used in seismic zones Easily adapted to enable mounting building systems Easy project implementation giving designers greater versatility Fire resistant through fireproofing

PRODUCTION PROCESS:

02 1 Preparing casting beds of slab

5 Marking and identifying slabs

Hollow core slab

6 Making openings

2 Pulling and attaching prestressing wire or strand

7 Curing and inspection of long slabs

3 Prestressing

8 Cutting slabs to delivery lengths

4 Forming slab around the reinforcement

9 Lifting slabs to stockyard stacks

PROPOSED IBS COMPONENTS

It is typically used in the construction of floors in multistory apartment buildings.

It offers the ideal structural section by reducing deadweight while providing the maximum structural efficiency within the slab depth.

17

SLAB

18 The hollow core slab is supported by a universal steel I-beam of 175mm x 250mm.

CONNECTION DETAILS

Hollow core slab to steel beam connection detail

i) Internal Support

Available Sizes Precast hollow core slabs are manufactured in the factory into various modular dimensions, with increments of 25, 50 or 100mm.

iii) Secure Connection

PROPOSED IBS COMPONENTS

ii) Edge Support

02

19

SLAB CONNECTION DETAILS

Hollow core slab to steel beam connection detail

i) Internal Support

Insitu concrete or grout fill along shear key joints

Insitu concrete Hollow core slab

Tr a n s v e r s e reinforcement

Insitu concrete

02 Milled slot Hollow core slab

Grout

Steel I beam

Stirrups Transverse reinforcement

Sectional detail

Steel I beam

PROPOSED IBS COMPONENTS

1 inch minimum grout

SLAB CONNECTION DETAILS

Hollow core slab to steel beam connection detail

20 ii) Edge Support Insitu concrete or grout fill along shear key joints

Stirrups

Insitu concrete

Tr a n s v e r s e reinforcement

Insitu concrete

Hollow core slab

Milled slot

Grout

Hollow core slab

Steel I beam

Transverse reinforcement

Sectional detail iii) Secure connection

Insitu concrete Hollow core slab

Welded plate (1 per plank) Steel I beam

PROPOSED IBS COMPONENTS

Steel I beam

02

WALL The proposed apartment uses precast concrete wall.

Precast concrete wall systems can be comprised of a variety of shapes, and wall types, which typically fall into three basic categories: solid, sandwich and thin-shell. These can be panelized and erected in either a horizontal or vertical position and used on all types of structures from residential to commercial, institutional to industrial.

ADVANTAGES OF PRECAST CONCRETE WALL PANEL: • High versatility. Able to produce concrete of different colors, texture and sizes • High quality as made in a controlled environment • Quick installation for reduced on site labor needs and costs.

• High thermal mass reduces fluctuation of temperatures within the buildings • Minimal Maintenance needed, which only includes occasional cleaning over several year

PRODUCTION PROCESS:

Precast concrete wall

02 1 Concrete is premixed with small aggregates of crushed rock, sand and water.

5 Concrete is poured into the form and flows around the steel reinforcement. This layer forms the first half of the sandwich.

2 The mould of the precast concrete wall is created. A spray agent is released on the casting form.

6 A rigid foam insulation is placed at the center of the sandwich. It is studded with protrusions to secure it to the concrete.

3 High strength steel cables are strung throughout the form with each cable pulled to a specific tension by a hydraulic device.

7 More steel reinforced concrete completes the sandwich.

4 Rebar cages and welded wire mesh are inserted into the form.

8 The precast concrete is ready to be used after 3 days of curing.

PROPOSED IBS COMPONENTS

Wall panels can be designed as non-load bearing or load bearing, carrying floor and roof loads, as well as lateral loads.

21

WALL

22 i) Intersecting 90° corner connection

CONNECTION DETAILS

Precast concrete wall connection detail

Insulated Wall Panel

Steel L angle INTERIOR

EXTERIOR Caulking and Backer Rod to seal

Cast in plate

Coil Loop insert, washers, bolts and slotted plate

02 PROPOSED IBS COMPONENTS

INTERIOR

Sectional detail ii) Panel to Panel connection

Coil Loop insert, washers, bolts and slotted plate Wall Panel

13mm chamfer

Caulking and Backer Rod to seal

INTERIOR

Sectional detail

EXTERIOR

Coil Loop insert, washers, bolts and slotted plate

WALL

23 iii) Beam connection

CONNECTION DETAILS

Precast concrete wall connection detail

Insulated Wall Panel

Structural Steel beam

Cast in plate for structural connection

02 INTERIOR

Sectional detail iv) Panel to column connection Window, Frame and Caulking by others

Connection Window/Door panel by others

Steel Column

Slotted Angle by others

of to

Threaded Rod

Precast Wall Panel Halfen (Vertical)

Anchor

Plastic Shims

EXTERIOR

INTERIOR

Sectional detail

PROPOSED IBS COMPONENTS

EXTERIOR

24

STAIRCASE

ADVANTAGES OF PRECAST CONCRETE STAIRCASE:

The proposed apartment uses precast concrete stairs.

• The monolithic (as one unit) top and bottom landings eliminate the need of forming landings on-site and the need for temporary stairs during construction.

• Advanced mechanical connection, speeds the installation process along with eliminating the need of propping (temporary supports).

• Precast stairs are designed and manufactured to any specific floor height and application.

• These are durable and maintenance free.

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

• Better quality control.

• Positioned and fixed by semiskilled labour.

Precast concrete stairs are available in various configurations from a single stair flight to a complete precast stair well with landings. The landings can be designed as individual units or can be manufactured as complete precast stair flight and attached landing. Methods of connection is fabricated along with the staircase to allow on-site assembly.

Precast Concrete Staircase

CONNECTION DETAILS:

02

Staircase connection

Hollow core slab landing

floor

PC landing slab Staircase tongue joint

Floor joint

slab

groove

PROPOSED IBS COMPONENTS

Concrete screed

25

STAIRCASE

i) Precast concrete staircase to hollow core slab connection

CONNECTION DETAILS

Concrete screed

Bars from RC stairs

Precast concrete staircase connection detail Precast hollow core slab Universal I-beam

Steel angle support bolted to PC stairs

steel

Sectional detail

02

ii) Precast concrete staircase to precast concrete landing slab connection

Bars from RC stairs

PC landing slab Bars from RC stairs

Concrete screed

Precast concrete staircase with 9 risers Riser height: 172mm Tread depth: 275mm PC landing slab

PROPOSED IBS COMPONENTS

Concrete screed

26

ROOF TRUSS ADVANTAGES OF STEEL ROOF TRUSS: A roof truss is made of individual members with equal counteracting tensile and compressive forces, its purpose is designed to behave as a single object which supports a load over a span.

A truss system design is comprised of 3 members, a top chord, a bottom chord and interior members called webbing or webs. These interior members combine to form a simple system of triangles creating equilibrium of forces within the truss system.

• Lightweight and quick installation • Steel roof trusses can spand great lengths compared to wooden trusses • A standard truss is a series of triangles - a stable geometric shape that is difficult to distort under load • These triangles combine to distribute the load across each of the other members, resulting in a light structure that is stronger than the sum of the strength of its individual components.

• Pest resistance • Fire resistance

Steel roof truss

The proposed steel framing system for the apartment uses prefabricated steel roof truss.

02 PROPOSED IBS COMPONENTS

PRODUCTION PROCESS:

1

2 Cutting The metal is cut using plasma cutters, lasers, and water jets.

3 Baking and Rolling Press baking and rolling allow for an enormous range of metal thicknesses, sizes, and shapes for versatile applications.

Screwing Truss pieces are laid out and hold in place to be attached with screws. The assembled truss is banded together and transported for storage

27

ROOF TRUSS CONNECTION DETAILS

Steel roof truss to steel I beam connection detail

Internal wall bracket

Bottom chord of truss

Steel H column

PROPOSED IBS COMPONENTS

Steel I beam

02

28

TOILET POD ADVANTAGES OF TOILET POD: Toilet pods are prefabricated selfcontained fully functioning toilet units that are prefabricated and manufactured off site, pressure and electrically tested.

They are preinstalled with bath or shower, basin, cabinets, lights and mirrors, contained in a steel frame with wooden panels, finished with tiles and waterproof lining, with plumbing and electrical components are connected.

• The toilet pods are made in controlled manufacturing conditions, and on tight inventory control and project schedules.

• The offsite construction method also allows the bathroom pod manufacturer the ability to research and implement aesthetic and functional innovations to better improve the quality of the bathroom pod.

• The cost savings that can be made by building repeated designs in a factory environment • Higher quality finish • Rapid installation • No trades on site

Toilet pod

02

Integrated, pretested plumbing and electric, code compliant and ready for final hookup Waterproof, thin profile subfloor supports any floor finish while providing a seamless transition to the adjoining floor

Steel blocking for shower heads, tub spouts and well mounted accessories

Completely finished interior clean and ready to use

PROPOSED IBS COMPONENTS

Moisture- resistant, abuseresistant wallboard, glued and screwed to framing

Steel framing engineered for superior strength and accuracy

03

SEQUENCE OF CONSTRUCTION Construction On Site Construction of Scaled Model

03

30

CONSTRUCTION ON SITE FOUNDATION (CAST IN-SITU CONCRETE)

A well-designed foundation is crucial for any steel structures or any building. It ensures durability and stability of the structure and is the base for construction.

Depending on the soil bearing capacity of the site, reinforced concrete pad footings are usually applicable, which distributes and transfers single point load from the columns to the ground (soil layer).

A suitable foundation system for the erection of a steel framing system is discussed.

1

SETTING OUT

After the position is determined, the site is excavated for the setting up of formworks for pad footings.

2

FORMWORK

Formwork is laid down for the forming of pad footings.

3

REBAR

Rebar (placed on top of spacer blocks) is used to increase strength and provide tension properties for the concrete.

03 SEQUENCE OF CONSTRUCTION

4

ANCHOR BOLT

Anchor bolt serves as the connection to the steel column which will be installed on-site.

5

POURING CONCRETE

Concrete of suitable ratio is used to make sure the foundation of the building has sufficient strength.

Concrete footing with base plate connection.

6

CURING

Concrete is allowed to cure to avoid excessive loss of water that will reduce its strength.

When the concrete has cured properly, the formwork can be dismantled for the next step in construction.

31

CONSTRUCTION ON SITE COLUMN (PREFABRICATED STEEL COLUMN) Steel columns are joined to the foundation through a steel base plate which is welded to it. A base plate is necessary to distribute the column load over an area wide enough so that the allowable stresses in the concrete are not exceeded.

The base plate connection is bolted to the pad footing while making sure the steel column is aligned using packing plates.

Once alignment is done, grouting is the next step to further ensure the strength of the connection.

1

ASSEMBLY

Prefabricated steel columns are brought to site and held using specialised machinery such as truck cranes.

2

BOLTING

Steel column is bolted to the concrete footing through the base plate provided by the anchor bolt.

3

GROUT

Structural grout is added to strengthen the connection.

03 SEQUENCE OF CONSTRUCTION

BEAM (PREFABRICATED STEEL BEAM)

1

ASSEMBLY

Prefabricated steel beams are brought to site and held using specialised machinery such as truck cranes.

Steel frame structure.

2

BRACING

Steel components may be paired with temporary bracing to allow quick and level installation of beams.

3

BOLTING

Steel beam is bolted to the steel column once the level is straight.

32

CONSTRUCTION ON SITE ROOF (PREFABRICATED STEEL ROOF TRUSS) The roof is the final component utilising prefabricated steel system, which forms the complete steel frame structure of the 3-storey apartment.

1

MARKING

Position of the roof truss is marked on the column and beams to the required spacing to ease installation.

2

ASSEMBLY

Special machinery is used for the placing of the roof truss on the column and beams.

3

BRACING

Temporary bracing is installed to prevent lateral movement, especially in unfavourable weather conditions.

03 SEQUENCE OF CONSTRUCTION

4

BOLTING

Once the roof truss is in place, it is bolted to the beams and columns.

Roof structure.

33

CONSTRUCTION ON SITE FLOOR (PRECAST HOLLOW CORE SLAB) Due to hollow core slab’s modularity, construction process can be done in a quicker manner as the installation process is not troublesome.

1

TRANSPORT

Precast hollow core slab is transported to the construction site in specific sizes.

2

ASSEMBLY

Special machinery is used for the placing of the slabs on the steel beams.

3

PLACEMENT

Equal spacing between the slabs is maintained to allow for efficient installation.

03 SEQUENCE OF CONSTRUCTION

4

DROP POINT

Different thickness is used to provide a drop point for specific areas.

Floor structure.

5

GROUT

Prefabricated steel beams are brought to site and held using specialised machinery such as truck cranes.

6

FLOOR

Multiple slabs when grouted together can act as one continuous floor.

34

CONSTRUCTION ON SITE TOILET POD The usage of toilet pod allows for a efficient and modular construction of the interior space. It will also reduce construction period significantly.

1

ASSEMBLY

Prefabricated toillet pod is hoisted into the building structure using lifting cranes.

2

INSTALLING

The pod is set up at the screened level.

3

EXTERIOR

The exterior of the toilet pod is treated with the same finishes as the rest of the room to blend in.

03 SEQUENCE OF CONSTRUCTION

35

CONSTRUCTION ON SITE STAIRCASE (PRECAST CONCRETE STAIRS) The precast concrete staircase contains of two components: the landing and the run of the stairs. They are connected using bolts to each other and to the structural steel beam.

1

ASSEMBLY

The staircase unit is lifted from its storage space on site using a crane and transported to the placement of the stairs.

2

INSTALLING

The landing of the precast concrete stairs is installed and secured onto the structural beam of the building.

3

CONNECTING

Steel support angles help to secure the stair flight to the groove of the landing.

03 SEQUENCE OF CONSTRUCTION

4

LEVELING

A layer of cement screed is applied to level out the landing.

5

RAILING

The railings are installed in the precast unit and held in place with bolts.

Staircase for ease of circulation during construction.

36

CONSTRUCTION ON SITE WALL (PRECAST CONCRETE PANEL) The exterior of the steel frame structure is covered with a precast concrete panel which allows for a uninform finishing as it is constructed off-site.

1

SETTING OUT

Set reference line and offset line to determine the position of the precast elements to be installed.

2

ASSEMBLY

Lift and rig the panel to its designated location with the use of wire ropes.

3

PLACEMENT

Adjust the panel to position and secure it with diagonal props.

03 SEQUENCE OF CONSTRUCTION

4

SEALING

Prepare and apply non-shrink mortar to seal the gaps along the bottom edge of the inner side of the panel.

Exterior wall cladding.

5

CURING

Keep the installed panels undisturbed for at least 24 hours.

37

CONSTRUCTION OF SCALED MODEL 1:25 scaled model

2

FOUNDATION

The base for foundation concrete pad footing is set up according to a pre-determined position.

5

Hollow core slab standardized dimension used as the floor system.

Steel column is attached to the base plate of the pad footing.

6

FLOOR of is

STEEL COLUMN

STAIRCASE

Precast concrete stair is installed to allow ease of construction.

3

STEEL FRAME STRUCTURE Steel columns and beams make up the steel frame structure.

7

INTERIOR WALL

Interior walls of precast concrete panel is set up.

4

ROOF TRUSS

Roof trusses is installed in a 1200mm interval.

8

EXTERIOR WALL

Precast concrete panel is fixed onto the exterior of the apartment.

SEQUENCE OF CONSTRUCTION

1

03

04

TECHNICAL DRAWINGS Orthographic Drawings and Specification Schedules

04

A

B

D

C

E

F

39

H

G

Ai Aii Aiii

Gi Gii Giii

A'

FLOOR AREA SCHEDULE (sqm) W1

1

W1

W1

BALCONY

W1

2

BALCONY

9

BEDROOM

LIVING

W1

UP

8

D2

2i

W1

10

7

11

6

12

5

13

4

14

3

15

2

16

1

17

D2 BEDROOM

LIVING

B'

B

W3

D3

BATHROOM

W3

BATHROOM DP 50

D4

D1

3

D4

D1

DP 50

6.55

Living Room

13.56

Dining Room

11.14

Kitchen

7.75

Master Bedroom

15.79

Master Bathroom

4.47

Bedroom

14.97

Bathroom

2.99

Balcony

5.81

Total floor area of one unit W1 DINING

W1

68.82

W1

MASTER BEDROOM

FOYER

FOYER

DINING

D3

MASTER BEDROOM

D3

W1

4 D4

5

DP 50

MASTER BATHROOM

W3

KITCHEN

W2

KITCHEN

W2

MASTER BATHROOM

DP 50

D4

W3

A

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Ground Floor Plan

SCALE 1:100

DRAWING NO. 101.CD.101

SHEET NO. 1/17

04 TECHNICAL DRAWINGS

D3

Foyer

A

B

D

C

E

F

40

H

G

Ai Aii Aiii

Gi Gii Giii

A'

W1

1

W1

W1

BALCONY

W1

2

BALCONY

9

BEDROOM

LIVING

W1

UP

8

D2

2i

FLOOR AREA SCHEDULE (sqm)

W1

10

7

11

6

12

5

13

4

14

3

15

2

16

1

17

D2 BEDROOM

LIVING

B'

B

W3

D3

BATHROOM

W3

BATHROOM DP 50

D4

D1

3

D4

D1

DP 50

6.55

Living Room

13.56

Dining Room

11.14

Kitchen

7.75

Master Bedroom

15.79

Master Bathroom

4.47

Bedroom

14.97

Bathroom

2.99

Balcony

5.81

Total floor area of one unit W1 DINING

W1

68.82

W1

MASTER BEDROOM

FOYER

FOYER

DINING

D3

MASTER BEDROOM

D3

W1

4 D4

5

DP 50

MASTER BATHROOM

W3

KITCHEN

W2

KITCHEN

W2

MASTER BATHROOM

DP 50

D4

W3

A

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE First Floor Plan

SCALE 1:100

DRAWING NO. 101.CD.102

SHEET NO. 2/17

04 TECHNICAL DRAWINGS

D3

Foyer

A

B

D

C

E

F

41

H

G

Ai Aii Aiii

Gi Gii Giii

A'

FLOOR AREA SCHEDULE (sqm) W1

1

W1

W1

BALCONY

W1

2

BALCONY

9

BEDROOM

LIVING

W1

UP

8

D2

2i

W1

10

7

11

6

12

5

13

4

14

3

15

2

16

1

17

D2 BEDROOM

LIVING

B'

B

W3

D3

BATHROOM

W3

BATHROOM DP 50

D4

D1

3

D4

D1

DP 50

6.55

Living Room

13.56

Dining Room

11.14

Kitchen

7.75

Master Bedroom

15.79

Master Bathroom

4.47

Bedroom

14.97

Bathroom

2.99

Balcony

5.81

Total floor area of one unit W1 DINING

W1

68.82

W1

MASTER BEDROOM

FOYER

FOYER

DINING

D3

MASTER BEDROOM

D3

W1

4 D4

5

DP 50

MASTER BATHROOM

W3

KITCHEN

W2

KITCHEN

W2

MASTER BATHROOM

DP 50

D4

W3

A

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Second Floor Plan

SCALE 1:100

DRAWING NO. 101.CD.103

SHEET NO. 3/17

04 TECHNICAL DRAWINGS

D3

Foyer

A

B

D

C

E

F

Ai Aii Aiii

42

H

G

Gi Gii Giii

A'

45°

45°

1 2 30°

2i

30°

B'

04

B

TECHNICAL DRAWINGS

3

30°

4

45°

45°

5

30°

A

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Roof Plan

SCALE 1:100

DRAWING NO. 101.CD.104

SHEET NO. 4/17

43 H

F

G

E

D

B

C

A

MAX. HEIGHT +14550

ROOF LEVEL +10550

D2

D1

04

D2

W1

W1

W1

TECHNICAL DRAWINGS

W1

D1

SECOND FLOOR LEVEL +7650

D2

W1

D1

D1

D2

W1

W1

W1

FIRST FLOOR LEVEL +4550

D2

W1

D1

W1

D1

D2

W1

W1

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Front Elevation

SCALE 1:100

DRAWING NO. 101.CD.111

SHEET NO. 5/17

44 A

B

C

D

E

F

H

G

MAX. HEIGHT +14550

ROOF LEVEL +10550

04 W3

W3 W2

TECHNICAL DRAWINGS

W2

SECOND FLOOR LEVEL +7650

W3

W3 W2

W2

FIRST FLOOR LEVEL +4550

W3

W3 W2

W2

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Back Elevation

SCALE 1:100

DRAWING NO. 101.CD.112

SHEET NO. 6/17

45

5

4

3

2

1

MAX. HEIGHT +14550

ROOF LEVEL +10550

04 W3 W1

W1

TECHNICAL DRAWINGS

W1

SECOND FLOOR LEVEL +7650

W3 W1

W1

W1

FIRST FLOOR LEVEL +4550

W3 W1

W1

W1

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Side Elevation 1

SCALE 1:100

DRAWING NO. 101.CD.113

SHEET NO. 7/17

46

5

4

3

2

1

MAX. HEIGHT +14550

ROOF LEVEL +10550

04 W3 W1

W1

TECHNICAL DRAWINGS

W1

SECOND FLOOR LEVEL +7650

W3 W1

W1

W1

FIRST FLOOR LEVEL +4550

W3 W1

W1

W1

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Side Elevation 2

SCALE 1:100

DRAWING NO. 101.CD.114

SHEET NO. 8/17

W1

WINDOW SCHEDULE

DOOR SCHEDULE

47

D1 D2

D1

W1 W1 W3

W1

W3 W2

D2

D2 D1

D3

Casement window with glass panel D1 D2

W3

Entrance door with fixed side panel

D2 D3

Sliding door with full glass panel

W1

W2

D4

D2 D3

W2

W3

D3 D4

Timber door with panel

TECHNICAL DRAWINGS

W3

04

D3

W1 D3 W3 Casement window with glass panelD2 W2

Timber door

Awning window with glass panel

W2

D4

D3 D4

W2 D3 D4

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE D4

Door and Window Schedule

D4

SCALE 1:50

DRAWING NO. 101.SD.501

SHEET NO. 9/17

48 HOLLOW CORE SLAB SCHEDULE

5

4

3

2

1

MAX. HEIGHT +14550

HCS1

Hollow Core Slab Modular size

1200mm

ROOF LEVEL +10550

D4

D3

D4

D3

HCS2

TECHNICAL DRAWINGS

W1

04

Hollow Core Slab Modular size

600mm

SECOND FLOOR LEVEL +7650

D4

D3

D4

D3

W1

FIRST FLOOR LEVEL +4550

D4

D3

D4

D3

W1

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Section A-A’

SCALE 1:100

DRAWING NO. 101.CD.121

SHEET NO. 10/17

49 H

G

F

E

D

C

B

A

ROOF LEVEL +10550

04 TECHNICAL DRAWINGS

SECOND FLOOR LEVEL +7650

FIRST FLOOR LEVEL +4550

GROUND FLOOR LEVEL (APRON) +1450

GROUND LINE +0.0

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE

Sectional Perspective B-B’

SCALE 1:100

DRAWING NO. 101.CD.122

SHEET NO. 11/17

50 STEEL SECTIONS SCHEDULE

A

B

C

D

E

F

H

G

C1

Ai Aii Aiii

Gi Gii Giii

H-column

C2

H-column

Dimension

Dimension

200mm x 200mm

150mm x 150mm

Flange thickness

Flange thickness

1

10mm

7.5mm

Web thickness

Web thickness

6.5mm

5mm

2 B1

2i

B2

I-beam

Dimension

Dimension

175mm x 250mm

125mm x 250mm

Flange thickness

Flange thickness

11mm

8mm

Web thickness

Web thickness

7mm

5mm

4

5

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE

Foundation Structural Plan

SCALE 1:100

DRAWING NO. 101.CD.131

SHEET NO. 12/17

04 TECHNICAL DRAWINGS

3

I-beam

51 STEEL SECTIONS SCHEDULE

A

B

C

D

E

F

H

G

C1

Ai Aii Aiii

Gi Gii Giii

H-column

C2

H-column

Dimension

Dimension

200mm x 200mm

150mm x 150mm

Flange thickness

Flange thickness

1

10mm

7.5mm

Web thickness

Web thickness

6.5mm

5mm

2 B1

2i

B2

I-beam

Dimension

Dimension

175mm x 250mm

125mm x 250mm

Flange thickness

Flange thickness

11mm

8mm

Web thickness

Web thickness

7mm

5mm

4

5

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE

First, Second Floor Structural Plan

SCALE 1:100

DRAWING NO. 101.CD.132

SHEET NO. 13/17

04 TECHNICAL DRAWINGS

3

I-beam

52 STEEL SECTIONS SCHEDULE

A

B

C

D

E

F

H

G

C1

Ai Aii Aiii

Gi Gii Giii

H-column

C2

H-column

Dimension

Dimension

200mm x 200mm

150mm x 150mm

Flange thickness

Flange thickness

1

10mm

7.5mm

Web thickness

Web thickness

6.5mm

5mm

2 B1

2i

B2

I-beam

Dimension

Dimension

175mm x 250mm

125mm x 250mm

Flange thickness

Flange thickness

11mm

8mm

Web thickness

Web thickness

7mm

5mm

4

5

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Roof Structural Plan

SCALE 1:100

DRAWING NO. 101.CD.133

SHEET NO. 14/17

04 TECHNICAL DRAWINGS

3

I-beam

A

B

C

D

Ai Aii Aiii

E

F

H

G

53

Gi Gii Giii

1 2

04

2i

TECHNICAL DRAWINGS

3

4

5

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Roof Truss Plan

SCALE 1:100

DRAWING NO. 101.CD.134

SHEET NO. 15/17

54

RF3 RF3 RF3 RF3 RF3 RF3

RF3 RF3 RF3 RF3 RF3 RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

RF3

04

RF3

TECHNICAL DRAWINGS

RF2

RF1

RF1 RF1 RF3 RF3

STEEL SECTIONS SCHEDULE

RF3

RF1

RF3 RF3

RF1

RF1

C-channel

RF2

C-channel

RF3

Purlin

Dimension

Dimension

Dimension

75 x 250 x 5mm

50 x 100 x 5mm

82 x 42 x 2mm

RF2 RF1

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE Roof Truss Detail

SCALE 1:50

DRAWING NO. 101.CD.141

SHEET NO. 16/17

55

04 TECHNICAL DRAWINGS

PROJECT TITLE

Building Technology I [BLD61403] Project I: Industrialized Building System

DRAWING TITLE

Exploded Axonometric

SCALE 1:250

DRAWING NO. 101.CD.151

SHEET NO. 17/17

05

IBS SCORE IBS Score Calculation

05

57

IBS SCORE CALCULATION AREA (m²) / LENGTH (m)

IBS Factor

Coverage

IBS Score

226.15

1.0

(226.15 / 919.50) = 0.25

(0.25 x 1.0 x 50) = 12.5

(226.15 x 2) = 452.30

1.0

(452.30 / 919.50) = 0.49

(0.49 x 1.0 x 50) = 24.5

05

Steel columns and beams + No floor (2nd floor)

226.15

1.0

(226.15 / 919.50) = 0.25

(0.25 x 1.0 x 50) = 12.5

Steel columns and beams + No floor (precast stair)

14.90

1.0

(14.90 / 919.50) = 0.01

(0.01 x 1.0 x 50) = 0.5

IBS SCORE

ELEMENTS

919.50

-

1

50/50

Internal wall: Precast concrete panel

(17.97 x 3) = 53.91

1.0

(53.91 / 190.64) = 0.28

(0.28 x 1.0 x 20) = 12.5

External wall: Precast concrete panel

(45.58 x 3) = 136.73

1.0

(136.73 / 190.64) = 0.72

(0.72 x 1.0 x 20) = 24.5

190.64

-

1

20/20

Part I: Structural System (max 50 pts.)

Prefab metal roof truss Steel columns and beams + Precast hollow core slab (Ground floor and 1st Floor)

Total Part 1 Part 2: Wall System (max 20 pts.)

Total Part 2

58

IBS SCORE CALCULATION ELEMENTS

AREA (m²) / LENGTH (m)

IBS Factor

Coverage

IBS Score

Steal beam and column sizes not included in MS 1064

-

-

0

0

0% of wall sizes follow MS 1064 part 10:2001

-

-

0

0

100% of slab sizes follow MS 1064 part 10:2001 (thickness 150, 200mm with width 600, 1200mm)

-

-

100

4

50% of door sizes follow MS 1064 part 4:2001 (width of 9M, 15M with height of 21M)

-

-

50

2

100% of window sizes follow MS 1064 part 5: 2001 (12M x 15M, 15M x 10M, 6M x 7M)

-

-

100

4

Repetition of floor to floor height (31M) = 100%

-

-

100

2

Vertical repetition of structural floor layout = 100%

-

-

100

2

Horizontal repetition of structural floor layout = 100%

-

-

100

2

Total Part 3

-

-

-

16/30

Part 3: Other Simplified Construction Solutions (max 30 pts.)

86

IBS SCORE

IBS CONTENTS SCORE OF PROJECT (PART 1 + 2 + 3)

05

06

CONCLUSION

06

CONCLUSION

60

The proposed apartment applies Industrialised Building System (IBS) such as steel framing system, precast concrete walls and staircase, prefabricated roof trusses and hollow core slab. Hence, it has achieved an IBS score of 86% due to the application and usage of prefabricated and precast components, modular components, and standard dimensions fulfilling the requirement as stated in MS1604.

Achieving a high IBS score would provide various benefits in terms of reducing construction time, less wastage and have higher quality control.

The steel framing system itself brings about great efficiency in the construction process of buildings due to its light weight properties and quick prefabrication process Thus, the concept of IBS should be widely promoted and discussed to help futher boost and enchance the construction industry in terms of performance and efficiency. Futher research can be conducted to bring awareness and educate the current and future IBS users to increase its application here in Malaysia as it brings a multitude of benefits to many.

06 CONCLUSION

Final model of proposed apartment

07

REFERENCES

07

REFERENCES

62

BOOKS Guide to modular coordination in buildings: MS 1064. (2001). Shah Alam: Department of Standards Malaysia.

Ching, F. D. (2014). Building Construction Illustrated. New Jersey: John Wiley & Sons.

Uniform Building By-Laws 1984 (1997). Compiled by Legal Research Board. International Law Book Services, Kuala Lumpur.

WEBSITES

CCSM. (n.d.). Retrieved from https://ame-engi.com.my/project/ccsm/ Choma, D., & Choma, D. (n.d.). EPS foam used as insulation in precast concrete wall panels - PolyMolding LLC. Retrieved from http://polymoldingllc.com/ precast-concrete-wall-panels/ Concrete Stairs, Precast Concrete Stairs, Precast Stairs Landings. Retrieved from http://www.acp-concrete.co.uk/precast-concrete-products/floors-and-stairs/ concrete-stairs/ Construction of Steel Structure Foundations, Columns, Beams, Floors. (n.d.). Retrieved from https://theconstructor.org/structures/construction-steel-structurefoundations-columns-beams-floors/18648/ Don’s Works. (n.d.). Retrieved from http://cgetechnology.blogspot.com/2011/12/simple-method-statement.html Hollowcore Production Cycle - Prestressed Hollow Core Slabs. (2017, July 17). Retrieved from http://www.ultraspan.ca/the-hollowcore-production-cycle/ Installation of Hollow Core Floor Slabs (n.d.). Retrieved from https://www.betonika.lt/files/parsisiust/montavimo_instrukcijos/montavimo_rekomendacijos_ en/installation_of_hollow_core_floor_slabs_en.pdf Installation of Precast Concrete Hollow Core Planks | INDIAPRECAST. (n.d.). Retrieved from http://www.indiaprecast.com/hollow-core-slab/installation-ofplanks.html

REFERENCES

Advantages of Precast Concrete. (2017, February 22). Retrieved from http://www.metromont.com/7-advantages-of-precast-concrete

07

REFERENCES

63

WEBSITES Pad foundation - Designing Buildings Wiki. (2016). Retrieved from https://www.designingbuildings.co.uk/wiki/Pad_foundation Portal Rasmi CIDB. (n.d.). Retrieved from http://www.cidb.gov.my/index.php/my/ Shadestudio (2018). Precast Stairs. Retrieved from http://oranmore.co.uk/products/precast-stairs/ Steel frame - Designing Buildings Wiki. (2016). Retrieved from https://www.designingbuildings.co.uk/wiki/Steel_frame The Basic Guide to Precast Concrete Stairs. (2014). Retrieved from https://gharpedia.com/precast-concrete-stairs/

What is Precast Concrete? What Are the Advantages? Nitterhouse Concrete. Retrieved from https://nitterhouseconcrete.com/what-is-precast-concrete/

REFERENCES

The Benefits of a Precast Wall Panel System - Wells Concrete. (2012). Retrieved from https://www.wellsconcrete.com/blog/benefits-precast-wall-panel-system/

07