Construction Analysis (ABPL2003) - The Cave House

ABPL20033 - Construction Analysis Semester 2 - 2017 Dr Alberto Pugnale – Subject coordinator Dr Sofia Colabella – Senior Tutor Timothy Derham – Tutor Melissa Chong, 864703, 5 October 2017 The Cave House by Mcbride Charles Ryan, Tutorial 7

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STAGE 1 : EXCAVATION AND SERVICES

STAGE 2 : BASEMENT RETAINING WALLS AND FOOTINGS

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STAGE 3 : BASEMENT RETAINING WALL AND GROUND FLOOR SLAB

STAGE 4: FIRST FLOOR STRUCTURE

STAGE 5: INTERMEDIATE FLOOR JOIST

STAGE 6: FIRST FLOOR FRAMING AND PROPS

STAGE 7: ROOF STRUCTURE

STAGE 8: ROOF COVER

STAGE 9: WINDOWS, CLADDING AND SERVICES

STAGE 10: SERVICES, INSULATION

STAGE 11: CEILINGS AND PARTITIONS

STAGE 12: FINISHING TRADES

STAGE 1 : EXCAVATION AND SERVICES 1.

2.

Excavation for basement using a bob cat excavator Installation of in ground services (drainage, hot water supply, stormwater)

Boundary fences are installed to protect the adjacent houses from the dust produced during construction.

The land was previously unoccupied, thus bulk excavation was carried out. A bob cat excavator with a back hoe was used to remove the existing vegetation and some rocks, allowing an even foundation to be achieved.

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20mm diameter Hot water supply pipe

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90mm diameter Drainage pipe This main drainage pipe collects waste from the secondary drainage pipes and transports them to the main sewer point (the lowest point on site).

90mm diameter slotted PVC pipe in filter sock These secondary drainage pipes are downward sloping so as to ensure a smooth flow of waste via gravity. They are connected to the main drainage pipe at an angle, so as to prevent possible clogs at the joints, which may cause the sewage system to fail.

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Site visits would be arranged to locate the position of these underground services.

Plumbers are engaged to install drainage pipes and stormwater pipes, which would be connected to a shared legal point of discharge.

100mm diameter Stormwater pipe This pipe collects stormwater from the stormwater pipes on the roof and transports them to the legal point of discharge.

BASEMENT PLAN: SERVICES Waste from construction are collected in a main cage for easy disposal.

STAGE 2 : BASEMENT RETAINING WALLS AND FOOTINGS 1.

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3.

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Delivery of steel reinforcement bars Installation of strip footings, pad footings and buttress footings Addition of gravel bed Installation of water proofing membrane Starting to erect basement retaining walls and columns Concrete columns are cast in situ and are located above pad and buttress footings. This is because concrete columns carry point load,which has a larger force per unit area, as compared to a uniformly distributed load. Thus larger and thicker concrete footings are required to absorb the forces.

Basement retaining walls are made of concrete masonry units that are produced offsite and delivered as individual units.

Use of reinforced concrete Concrete cracks and fails under tension. Thus, steel, being strong in tension, helps counter the tensile forces in the slab, column and retaining walls. Steel is prone to corrosion when in contact with water, thus must be positioned within the concrete.

Gravel

Buttress footing Exterior strip footing 400 deep and 500 wide with N12 starter bars at 400 centres

400x700x2100

Interior strip footing 400 deep and 300 wide with N12 starter bars at 400 centres

Dowel bars Pad footing 1800x1400x400deep SL02 mesh top N16 bars at 200 centres

3-N16x550 at 100 centres top and bottom,150mm embedded into previous pours They are short steel bars that provide a mechanical connection between the pad footing and the buttress footing without without restricting horizontal joint movement.

Water proofing membrane It protects the steel reinforcement and concrete from the soil moisture, which prevents corrosion

BASEMENT PLAN : FOOTING REINFORCEMENT Gravel bed SL02 mesh top Square mesh with edge side lapping wires 9mm diameter with 200 spacings

N16 Starter bars Normal ductility, 16mm diameter They help anchor and transfer the vertical loads from the concrete block wall to the strip footings.

N16 reinforcing bars at 200 centres Normal ductility, 16mm diameter at 200 spacings

N16 reinforcing bars at 200 centres Normal ductility, 16mm diameter at 200 spacings

Bar chairs

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SECTION DETAIL: PAD FOOTING

They hold the reinforcing bars to a certain position so as to: 1.ensure sufficient concrete cover to prevent corrosion 2. allow the reinforcement bars to work optimally in tension

STAGE 3 : BASEMENT RETAINING WALL AND GROUND FLOOR SLAB 1.

2.

3.

4.

5.

Pouring and curing of the basement concrete slab Backfill and installation of concrete retaining wall Installation of temporary metal props and timber formwork Installation of steel reinforcement for ground floor slab Installation of pipes for hot water and drainage pipes for sauna

140mm thick reinforced concrete block wall

1000x500 reinforced concrete column It transfers point loads from the slab to the pad footings.

A thinner wall is used as it is for the interior, which in this case, plays no significant structural role.

190mm thick reinforced concrete block retaining wall

8N28 bars

A thicker wall is used to offer greater resistance against the lateral forces from the surrounding soil. It also functions structurally by transferring uniformly distributed vertical loads from the slab to the strip footing,

8 bars, normal ductility, 28mm diameter

3R10 Ligatures at 300 centres with 25mm cover

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PLAN DETAIL : COLUMN REINFORCEMENT

They prevent the vertical N28 bars from moving.

Water-proof membrane It protects the concrete retaining wall and steel reinforcements from moisture, which prevents concrete cancer.

Steel props to support the ground floor slab Basement concrete slab

Backfill They fill the void between the ground and the concrete retaining walls for support

Gravel bed Pad footing

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Stormwater pipe (roughed into slab) is capped off to prevent entry of dust particles.

The work as a form of crack control by safely absorbing the force released by the slab during expansion.

It is a perforated tube that collects water from the surrounding soil, and transports them to the legal point of discharge. This direct water away from the retaining wall, which prevents concrete cancer.

Due to insufficient anchorage length, starter bars are used to anchor the concrete block retaining walls to the ground floor slab and band beams.

This also optimises the transfer of forces from the ground floor slab to the footings .

Ligatures provide shear reinforcement for the band beams. They also prevent the movement of the reinforcing bars which ensures constant concrete cover, which reduces the chances of concrete cancer.

Foam expansion joint

Agi-drain

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Temporary metal props and timber formwork were assembled for the pouring of the ground floor slab.

SECTION DETAIL : CONCRETE RETAINING WALL Pipes are are retrofitted through the walls and the slab. Lights are also installed for the temporary site office in the basement.

Fluorescent safety caps were added to the ends of the protruding reinforcing bars for safety purposes.

Black waterproofing was added to the edge of the concrete slab to prevent damages from weathering.

STAGE 4: FIRST FLOOR STRUCTURE 1.

2.

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6.

Delivery of steel columns and timber studs Installation of steel columns along the perimeter of the building Installation of timber frames Connection of downpipe from above First floor services are roughed in Bracing and insulation are installed

75 x75 x8 Square hollow section

80mm Rebate 2-M-12x90 Embed chemsets These bolts anchor the base plate to the concrete slab

20 Nominal Grout leveling pad

90mm width x10mm high base plate

They position the base plate to the correct height

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This helps connect the steel columns to the slab more effectively. It also helps distribute the column load over an area so as to prevent failure at the joints.

Timber studs for the first floor framing were delivered to site individually. They were cut and erected on site because the internal walls are irregularly sized.

DETAIL: CONNECTION OF STEEL COLUMN TO GROUND FLOOR SLAB

Insulation It is installed at this stage because it must go under the plywood sheet bracing.

Down pipe for stormwater

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7.5kn/M rated plywood bracing in accordance to AS1684-1999

Triple Bottom Plate Ground floor concrete slab

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8N28 bars for band beam 8 bars, normal ductility 28mm diameter

DETAIL: BOTTOM PLATE AND PLYWOOD BRACING

Inner sheet bracing was installed on the internal walls before adding insulation. They help resist lateral forces like wind. Sheet bracing was placed specifically for the rooms in my section because the the external walls are made of glass, which are not as efficient in resisting those loads.

Steel columns are used alongside with glass to resist wind loads.

Additional noggings for extra lateral strength Hot water services for the sinks are roughed in 2 additional bottom plates were used.This provides a backing for the floor skirting which would be discussed later on.

Floor board attached to ground floor concrete slab

There are pocket recesses in the slab to make way for the steel columns. This would eventually be filled with grout which helps hide the connections between the perimeter steel columns and the slab.

STAGE 5: INTERMEDIATE FLOOR JOIST 1.

2.

3.

Scaffolding assembly Delivery and assembly of intermediate floor Rough ins of services and wiring

Additional horizontal timber studs are used to connect the C section beam to the vertical timber studs. (similar to a bottom plate)

A 76 x150 C section beam was used instead of a timber stud because this area requires greater resistance. This was based on the calculations and instructions from the structural engineer.

1.5mm Butynol membrane

Marine ply

It is used for waterproofing purposes

It provides a backing for the butynol membrane to effectively fasten itself onto the floor beam.

Floor beam 2 300 x 45 HYSPAN LVL that are nail plated (Located in a distance)

76x150 C section beam 2 M12 Bolts at 450mm centres

Packers parallel to the deck joist could be seen from a distance. This fills the gap between the marine ply base and the top of the HYSPAN LVL, which provides extra support for the flooring above.

Walling Plate 140x45 MGP10 Pine A waling plate is used to support the perpendicular connection between the C-section and the deck joist.

Deck Joist 200x45 HYSPAN LVL at 450 centres

Pryda framing bracket

75 x75 x8 Square hollow section

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This bracket is used to connect perpendicular members.

DETAIL: INTERMEDIATE FLOOR JOIST CONNECTION

Additional steel members are often added on site impromptu due to unforseen circumstances. This increases the intermediate floor structure’s capacity to carry more load.

HYSPAN LVL was used in my section because of the irregularly shaped floors. LVL is an engineered timber product that is made of several plywood sheets that are glued together.

They are cheaper and are able to cover longer spans. Their sizes could also be easily altered on site. Thus, HYSPAN LVL was used.

(This is not the final intermediate floor structure)

Electrical wires are stuck onto the base of the HYSPAN LVL deck joist Pryda framing bracket

Marine ply

Vents are roughed in

Scaffolding is used to support the workers working on the upper storey. It is often custom designed by an engineer and is done according to the safety regulations provided in the Australian Standards and the NCC. Electrical wires are held by the webs of posi-joists.

STAGE 6: FIRST FLOOR FRAMING AND PROPS 1.

2.

3.

Delivery of timber studs and erection of first floor frames Holes were made in the floor joists for installation of services and wiring Yellow tongue particleboard was laid Wind beam 89x89x5 Square hollow section (cranked)

Stud Wall to AS1684 Wind beam 89x89x5 Square hollow section (cranked)

Walling Plate

Wind beam -230 PFC and 230x 12 Plate

89 x45 MGP10 Pine

Welded Studs at 1200 mm centres

Stud Wall to AS1684 Walling Plate 89 x45 MGP10 Pine

230 PFC 230x12 Plate

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Wind beam

Walling Plate 89 x45 MGP10 Pine Lintels are orientated on its steeper end so as to carry the second moment of inertia more efficiently.

Stud Wall to AS1684

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DETAIL: CONNECTION OF WALL BEAM

These plastic sheets protect the timber frames from weathering. This prevents the timber frames from failing structurally.

A 230 PFC wall plate was used here to help resist wind loads.

Steel was chosen over timber because it is able to resist and receive larger loads more efficiently, especially when the forces are directed at an angle (from the downward slopping cranked wind beam).

Temporary timber props were used to support the timber frames

Services are roughed in

Batt insulation brought to site

It is also used to support the odd opening in the timber frame.

I was unable to find a photo that only illustrated the installation of the first floor framing, thus this photo (Stage 9) was used instead.

The yellow tongue particle board was already laid to allow the workers to install the the timber frames for the first floor.

It does not need to be protected because it is not the finished flooring

STAGE 7: ROOF STRUCTURE 1.

2.

3.

Box gutter installation Connection of downpipe made Overflow made

1 As my area only covers the gutter, downpipes and overflow for the roof structure, these components would be discussed, rather that the rafters and purlins

Rainwater head box Overflow An overflow is used to discharge surplus rainwater when the downpipe and rain water box has reached its maximum capacity. It directly releases water to the ground below.

150mm Stainless Steel Downpipe

Box gutter

Rainwater head box

Unfortunately I was unable to find a photo that only illustrated the of the downpipe and box gutter, thus this photo (Stage 10) was used instead.

PLAN: ROOF STRUCTURE Zinc flashing into stainless steel rainwater head box

Roof structure behind the gutter The 1 degree pitched roof is supported by 2-200x63 HYSPAN LVL roof beams that are spaced at regular intervals. These roof beams are fastened to the columns by 2-30x1.2 GI straps with 4-3.15 x 35 FH Nails at 60 centres per end and a PRYDA triple grip. The roof is braced with 3.0kN/m rated diagonal strap bracing for additional resistance from lateral forces and uplift.

Folded zinc capping to parapet beyond A one degree pitch is required to ensure a smooth flow of water into the gutter.

Rigid stainless steel mesh

This directs rainwater from the parapet into the gutter channel or the stainless steel rainwater head box. This also protects the timber frames from weathering.

Rigid stainless steel mesh

rain water

Stainless steel rainwater head box Being larger in size, it is able to hold a larger capacity of water, which would be useful during heavy rain.

150mm Stainless Steel Downpipe

37.5mm fall in 600mm width gutter over 7500mm (1:200 fall)

Spandek hi-ten sheet along the fall length

Overlapped so as to prevent water from seeping into the structure.

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SECTION DETAIL : PERPENDICULAR TO MY SECTION CUT

STAGE 8: ROOF COVER 1.

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5.

Assembly of roof rafters and purlins Addition of water proof membrane Addition of roof insulation Rough ins for services Addition of roof cladding

Lysaght KLIP-LOK 406 0.48BMT

My section only covers the area of the roof gutter, which was discussed in stage 7. Thus, for this stage, the area behind the roof gutter would be discussed instead.

48mm Zincalum Finish This roof sheeting has a profile that matches the Klip-lock clip, which ensures that it is being fastened properly. It has a zinc alum finish thats helps protect the roof sheeting from corrosion. Its corrugated surface is perpendicular to the gutter, thus, facilitates the effective transport of water from the roof to the down-pipe.

R2.5 Bulk Insulation Bulk insulation is made of foam containing air pockets that act as a barrier against heat transmittance via conduction and convection.

Overflow An overflow is used to discharge surplus rainwater when the downpipe and rain water box has reached its maximum capacity. It directly releases water to the ground below.

Klip-lock Clip This clip fastens the roof sheeting to the gutter and the purlins.

Instead of being nailed down, it clips the roof sheeting onto the purlin internally. This ensures that the structure remains water-tight.

This is important as the roof has a 1 degree inclination which is very susceptible to ponding. Ponding causes the roof sheeting to be in constant contact with water which could quicken deterioration and corrosion , especially once the zinc alum finish fades off.

Box gutter

Gutter Rainwater head box

This roof sheeting overlaps the gutter so as to prevent water from seeping into the structure. The gap between the underside of roof sheeting and the gutter would be further sealed with drips so as to prevent the entry of water into the building

A metal strap is used to attach the purlin to the rafter that runs in the perpendicular direction

Rafter

Purlin

PLAN DETAIL : AREA CUT

Lysaght ‘Klip-lok’ Bulk insulation Reflective Insulation Packers are used to fill the gap between timber structural members so as to provide extra support.

Reflective insulation Reflective insulation comes in the form of a sheet with a shiny aluminium surface. The foil faces the interior and is located under the bulk insulation. This allows radiant heat to be reflected back into the building. A 25mm on the underside of foil is required to facilitate thermal insulation.

STAGE 9: WINDOWS, CLADDING AND SERVICES 1.

2.

3.

4.

Water proof membrane installation COMTEX panel installation Pebble render finish installed and underside of cladding Installation of window frames without glass panel

At the study on the ground floor, a double glazed sliding door with a fly screen is fixed in between the steel columns. Beside it, a sing-glazed fixed glass panel is fixed in. On the first floor, a double glazed sliding door opening to the deck was installed. A hinged sashless sliding was also installed to the left of it. In addition, a single-glazed fixed glass that has a silicon butt-joint was also installed. This glazing channel is frameless. The cladding on the ground floor is mainly made of glass panels. The first floor has a pebble render that is laid on top of structural ply wood which is attached to the load bearing timber framed walls.

At the angled area, it is connected by a 0.8mmBMT folded zinc cleat that is fastened by a silicon sealant.

Packers parallel to the deck joist could be seen from a distance.

Pebble render

Deck Joist

Comtex panel

200x45 HYSPAN LVL at 450 centres

This panel provides a flat and smooth surface for the render to be attached to the external walls

Pryda framing bracket This bracket is used to connect perpendicular members

Water proof membrane

75 x75 x8 Square hollow section

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SECTION DETAIL : CLADDING DETAIL

R2.5 Insulation (to be put in stage 10)

1 Sample pebble for cladding

Double glazed window

Capral 425 series frame

Aluminium drip

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It directs the water out of the house and into the butynol membrane. This prevents water from coming up to the window by capillary action.

75 x75 x8 Square hollow section (in a distance) Pocket recess in concrete slab 90mm width x10mm high base plate

2-M-12x90 Embed chemsets Aluminium trimming is used on the underside of the cladding to seal the gap. This protects the external wall structure from weathering which could cause quicker failure (This photo was taken from Stage 10)

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The aluminium window frames are smaller than the openings created for them in the timber frames. This allows easy installation. Eventually, the gap between the frames and the opening would be sealed with timber packers.

SECTION DETAIL : WINDOW

COMTEX Panel

Water proof membrane This building paper protects the panel from water and moisture so as to prevent failure.

STAGE 10: SERVICES, INSULATION 1.

2.

3.

4.

AC UNIT installation Electrical wires for study roughed in Flooring for main deck Insulation for first floor installed

In the study, both mechanical and electrical services were fixed in. In the toilet, mainly plumbing service were fixed in. This includes the sewer and hot/ cold water systems. For the sauna, mainly mechanical services were roughed and subsequently fixed in. This comprises of heating, cooling and ventilation components.

Turpentine decking on graded treated pine joists

1.5mm Butynol membrane It is used for waterproofing purposes

45x40 floor Battens Marine ply It provides a backing for the buttony membrane to effectively fasten itself to the floor beam

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Floor beam

Wires for lighting

2 300 x 45 HYSPAN LVL that are nail plated (Located in a distance) Packers parallel to the deck joist are located in the distance. This is to fill the gap between the marine ply base and the top of the HYSPAN LVL so as to provide extra support for the flooring above.

AC Unit Diffuser

AC Unit Ducted split air conditioning unit

Deck joist 120 x 45 F17 at 450 centres

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PLAN DETAIL : SERVICES

SECTION DETAIL: FLOORING FOR MAIN DECK

Connections for the wires for lighting and ducts for other services are fitted in

Decking and sunshade installed

Services for the toilets are roughed in

STAGE 11: CEILINGS AND PARTITIONS 1.

2.

3.

Suspended ceiling installation Timber decking installation Wall installation

Timber decking 75x19 dressed timber turpentine decking with 2mm gaps, fixed with stainless steel twist shank dome head nails.

Stainless steel nails are used to prevent corrosion in the connections which could cause failure.

75 x75 x8 Square hollow section Floor joist 75x50 Treated pine joist It secures the timber decking to the battens. It also levels the timber decking to the correct height , which hides the bottom of the sliding door and steel columns.

Battens 50x25 battens help secure the floor joists to the butynol tanking membrane.

Butnyol tanking membrane This water proof membrane protects the concrete slab and its internal reinforcements from corrosion which could lead to concrete cancer. This is continued under the subsoil of the sliding door so as to direct the water away from the base of the sliding door.

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SECTION DETAIL: EXTERNAL TIMBER DECKING

Despite being the same room, the ceiling is angled at different heights. Thus, fluorescent string was used to outline its shape. The measurements of each side were recorded and a 13mm painted plasterboard was being cut out accordingly. Packers are not required as the size of each panel is easily alterable.

Ground floor concrete slab Electric cables Bulk insulation

Hooks

Timber structural frames

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Tape

Wires to suspend ceiling at an angle

Tape coat Diagonal bracing

Batt insulation Furring channel 13mm Suspended plasterboard

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SECTION DETAIL: EXTERNAL TIMBER DECKING

On the first floor, the main deck is lined with messmate timber decking.

Diagram showing the number of coats required

After the dimensions of each ceiling panel is obtained, plasterboard is being cut accordingly.

The edges between each panel is taped and painted over by a tape coat. This is followed by a second coat, and eventually a finished coat. This hides the gaps between the ceiling panels in case of poor workmanship.

STAGE 12: FINISHING TRADES 1.

2.

3.

4.

5.

6.

Furniture in the study room are fixed in Carpet laid Ceiling and walls are sanded and finished off Flooring for sauna and toilet are laid Glass for the windows are fixed in Services and machines are fixed in

The floors of bedroom 2,3 and the study are carpeted.In the study, 20mm wide slots in desktop are created for heat convention and circular cut outs are made in the wall for power cords.

Cupboard 20x40mm Anodised aluminium angle This is used to create a shadow line.

A shadow line helps seal the edge between wall and the carpet neatly.

Carpet Timber stud This allows the aluminium angle to be fastened to form a shadow line

Furniture for the study room is assembled. Built in book shelves with a spray enamel paint finishes along with a white melamine desks are installed.

The carpet is being laid at the last few stages to prevent damages during the construction process

Concrete slab

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SECTION DETAIL: CARPET AND JOINERY

The toilet is covered in an ‘urbanstone’ paver- 40mm gunmetal honed sealed (tiles).

Several layers of materials were used as a form of protection against water. If water comes in constant contact with the ground floor concrete slab, concrete cancer could occur causing the structure to fail.

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For the sauna, the walls, ceilings and floors are covered in western red cedar with a turpentine strip flooring. The turpentine layer is water resistant, thus protects the red cedar and the subsequent layers from water. An additional water proof membrane is added to prevent water from leaking to the ground floor concrete slab.

PLAN: FLOORING

Sinks and toilets are being assembled Ceilings are repainted and sanded for the final finish

The bathroom is lined with glass mosaic tiles and defects are rectified before the handover

Glass windows are fixed into the aluminium frames. This is carried out only at the at the last few stages to prevent scratches and damage during the construction process

ABPL20033 Construction Analysis Dr Alberto Pugnale – Subject coordinator Semester 2 - 2017