AAC IBS System - Blockwork System

Blockwork System Advanced Architectural Construction ( ARC60104 ) Project 1 : Industrialised Building System (IBS) Jemimah Siew San Le Lee Jia Hui L o w Z h e n g Ya n Rachel Lau Yi Xuen Ta n S z e L o n g

0334092 0334321 0334960 0335079 0334357

Tu t o r e d b y M r E d w i n C h a n Ye a n L i o n g

Content OI

Introduction

1.0 Introduction to Industrialized Building System (IBS) 1.1 Types of Industrialized Building System in Malaysia 1.2 Advantages of Industrialized Building System 1.3 Disadvantages of Industrialized Building System

O2

Blockwork System

O4

Precedent Study

4.1 Precedent Study 1 4.2 Precedent Study 2

O5

Technical Drawings

5.1 Architectural Plans

2.0 Introduction to Blockwork System

5.1.1 Ground Floor Plan

2.1 Types of Blocks

5.1.2 First Floor Plan

2.2 Advantages and Disadvantages of Blockwork System

5.1.3 Second Floor Plan

2.3 Consideration when Selecting Blocks

5.1.4 Roof Plan

O3

5.2 Elevations

Concept Framework

3.0 IBS Component 3.1 Concrete Masonry Unit 3.1.1 Types of Blocks used 3.1.2 Construction Method for CMU 3.1.3 Fabrication Process of CMU 3.1.4 Installation Process of CMU 3.2 Strip Foundation 3.3 Precast Hollow Core Slab 3.4 Precast Concrete Staircase 3.5 Lightweight Steel Roof Truss

5.2.1 North Elevation 5.2.2 East Elevation 5.2.3 South Elevation 5.2.4 West Elevation 5.3 Sections 5.3.1 Section A-A’ 5.3.2 Section B-B’ 5.4 Structural Plan 5.4.1 Foundation Plan 5.4.2 Roof Structure Plan

O6

Schedule of IBS Component

6.1 Concrete Masonry Unit Block 6.2 Precast Hollow Core Slab 6.3 Prefabricated Door 6.4 Precast Lintel 6.5 Prefabricated Window 6.6 Toilet Pod

08

Construction Sequence

09

IBS Score Calculation

10

Conclusion

11

References

6.7 Precast Staircase

O7

Construction Details

7.1 Wall to Foundation Connection 7.2 Wall and Beam Connection 7.3 Wall to Slab Connection 7.4 Wall and Column Connection 7.5 Wall to Wall Connection 7.6 Window to Wall Connection 7.7 Door to Wall Connection 7.8 Precast Staircase 7.9 Prefabricated Lightweight Steel Roof Construction 7.10 Lightweight Steel Roof to Beam and Wall Connection

OI Introduction 1.0 Introduction to Industrialized Building System (IBS) 1.1 Types of Industrialized Building System in Malaysia 1.2 Advantages of Industrialized Building System 1.3 Disadvantages of Industrialized Building System

1.0 INTRODUCTION TO INDUSTRIALIZED BUILDING SYSTEM (IBS) The industrialized building system (IBS) can be defined in which all building such as wall, slab, beam, column and staircase are mass produced either in factory or at site factory under strict quality control and minimal wet site activities. In another definition by Esa and Nuruddin (1998) claimed that IBS is a continuum beginning from utilizing craftsman for every aspect of construction to a system that make use of manufacturing production in order to minimize resource wastage and enhance value for end users. (Junid, 1986) clarified that elaboration of IBS whereby the IBS in construction industry includes the industrialized process which the components are conceived, planned, fabricated, transported and erected on site.

1.1 TYPES OF INDUSTRIALIZED BUILDING SYSTEM (IBS) IN MALAYSIA

Precast Concrete System

Blockwork System

Steel Formwork 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.

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 labor and materials. This includes the "tunnel form", the "lilt-up" beam system, "moulding form" columns and a permanent steel mould.

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 labor and materials. This includes the "tunnel form", the "lilt-up" beam system, "moulding form" columns and a permanent steel mould.

Steel Framing System

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.

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.

1.2

ADVANTAGES OF INDUSTRIALISED BUILDING SYSTEM (IBS) Less construction time Casting of precast element at factory and foundation work at site can occur simultaneously and the work at site is only the erection of IBS components which leads to earlier occupation of the building.

Cost savings The formwork of IBS components are made of steel, aluminum or other materials that allows for repetitive use.

Saving in labor When the IBS components are produced in factory, higher degree of utilization of machine is permitted and the use of labor will be reduced and lead to saving in labor cost.

Optimized use of material The utilization of machine during the production of IBS components lead to higher degree of precision and accuracy in the production.

Higher quality and better finishes Due to the careful selection of materials, use of advanced technology, better and strict quality assurance control since production in factory is under sheltered environment.

Construction operation less affected by weather The effects of weather on construction operation are less due to the fabrication of IBS components is done in factory while at site is only erection of the components.

Increase site safety and neatness Utilization of IBS components leads to less construction process especially wetwork at site that leads to the neater site condition and increase safety.

1.3 DISADVANTAGES OF INDUSTRIALISED BUILDING SYSTEM (IBS) High initial capital cost The initial cost including the cost of constructing the factory, casting beds and support machinery and the cost effectiveness can only be achieved when undertaking large projects.

Problem of joints Water leakage is often the major problem in building constructed using IBS. Sophisticated plants and skilled operators The prefabrication system relies heavily on sophisticated plants, which must be well coordinated and maintained by skilled operators. Breakdown in any one section would hold-up the entire production line.

Site accessibility IBS requires adequate sit accessibility to transport IBS components from factory to the site.

O2 Blockwork System 2.0 Introduction to Blockwork System 2.1 Types of Blockwork System 2.2 Advantages and Disadvantages of Blockwork System 2.3 Consideration when Selecting Blocks

2.0 INTRODUCTION TO BLOCKWORK SYSTEM

The Blockwork System is a type of IBS based on pre-cast concrete technology. The system includes hollow, interlaced and foaming pre-cast concrete blocks. Because of its small size if compared relative to other IBS components, it also allows installation to be done easily without the use of a lot of manpower and machines. It is available in different densities to suit different applications and it’s made up of cement, aggregate, water and admixture.

TYPICAL USES FOR CONCRETE BLOCK Concrete block is a popular construction material due to its versatility. It can be used for several applications, such as: Foundation Walls Basement Walls Partition Walls Exterior Walls These blocks can be finished with several coatings, which can be used to prevent water from penetrating the concrete and help with efflorescence.

Examples of theses types of coatings include: Cement Paints Latex Paints Oil-based Paints Urethanes Epoxy Coatings The specific type of coating will depend on the specific function of the block, where it will be used, if the coating needs to be UV resistant and breathable, etc.

2.1 TYPES OF BLOCKS A concrete block is sometimes known as concrete masonry unit (CMU), they can be solid or hollow and is available in many shapes and sizes. Concrete Blocks are sued for engineering and architectural purposes.

Solid Concrete Blocks Way denser and bigger than concrete bricks, solid concrete blocks are manufactured to be strong, heavy, and created out of naturally dense aggregates.

Paving Blocks Paving blocks are generally just a rectangular or square box made up of reinforced concrete. These blocks are used in paving and road shoulders and the common size of paving block is 60mm.

Aerated Autoclaved Concrete Block (AAC)

Concrete Bricks

Hollow Concrete Blocks

Aerated Autoclaved concrete blocks are lighter and bigger version of bricks. Mostly made with same ingredients as of bricks but with a different composition which made the material a vessel for cost-cutting.

Concrete bricks typically are small rectangular block arrange and piled systematically to create a rigid wall. Concrete brick are usually use in fences, facades, ad it provides the good aesthetic and slick look.

Concrete hollow blocks are usually manufactured using lightweight aggregates with a certain design load depending on the nature of the member it will be used into . There are two kind of concrete hollow blocks; load-bearing concrete hollow blocks and non loadbearing concrete hollow blocks.

Concrete Stretcher Block

Somewhat like corner block, concrete stretcher blocks are used to combine masonry units.

Concrete stretcher block is relatively the same with common hollow block, but their faces are laid parallel with respect to the face of the wall.

Lintel Blocks These concrete blocks are used in preparation for lintel beams.

Aesthetically, lintel blocks have a deep groove where reinforcing bars are put along with the concrete

Normally, concrete hollow blocks have voids of Âź its gross area and the solid area should be not less than half of its area to attain its maximum allowable load capacity, study suggests. It is available in sizes such as 100x200x400mm, 200x200x400mm,150x200x400 mm and so on.

2.2 ADVANTAGES AND DISADVANTAGES OF BLOCKWORK SYSTEM Advantages

Durable Can withstand extreme temperatures and weather conditions

High thermal mass Natural ability to reflect internal heat

Fire Safety Able to keep its structural integrity during an event of a fire

Installation time Blockwork walls can be built in a short period of time compared to use of masonry units due to its larger size

Disadvantages

Higher Cost Concrete blocks are much more expensive compared to materials such as timber

Plain and unappealing appearance The use of blocks can sometimes be unappealing to certain generic designs

Low-rise limit Blockwork system is usually implemented in low-rise structures

2.3 CONSIDERATION WHEN SELECTING BLOCKS

Appearance

Density

Load-bearing Characteristic

Weight & Handling Properties

Thermal Characteristic

O3 Concept Framework 3.0 IBS Component

3.1 Concrete Masonry Unit 3.1.1 Types of Blocks Used 3.1.2 Construction Method for CMU 3.1.3 Fabrication Process of CMU 3.1.4 Installation Process of CMU 3.2 Strip Foundation 3.3 Precast Hollow Core Slab 3.4 Precast Concrete Staircase 3.5 Lightweight Steel Roof Truss

3.0 IBS Component

Blockwork Components

Wa l l

Cast In-Situ

Precast

Prefabricated

Components

Components

Components

Strip

Hollow

Foundation

Core Slab Lightweight

Beams

Steel Roof Ground Columns

Floor Slab

Staircase

Tr u s s

3.1 CONCRETE MASONRY UNIT (CMU) A standard size rectangular block used in building construction

A pallet of “8-inch� CMU

An interior wall of painted CMU

CMU Exterior Wall

Lower density blocks may use industrial wastes, such as fly ash or bottom ash, as an aggregate. Recycled materials, such as postconsumer glass, slag cement, or recycled aggregate, are often used in the composition of the blocks. Use of recycled materials within blocks can create different appearance in the block, such as a terrazzo finish, and may help the finished structure earn LEED certification. Lightweight blocks can also be produced using autoclaved aerated concrete.

Concrete Masonry Units provide strength, durability, fire resistance, energy efficiency, and sound attenuation to a wall system. In addition, Concrete Masonry Units are manufactured in a wide variety of sizes, shapes, colors, and architecture finishes achieve any number of appearances and functions.

Strength & Durability

Fire Resistance

Time Efficient

Energy Efficient

Sound Attenuation

3.1.1 Types of Blocks Used

Hollow Concrete block – Wall The drawbacks of random rubble masonry, common in many hilly areas, are the excessive use of stones, mortar and labor, also its non-uniformity and the risk of water penetration.

By precasting the stones into uniform concrete blocks these drawbacks are eliminated.

200mm

Solid Concrete Block – Floor Slab

100mm

A concrete slab is a common structural element of modern buildings, consisting of a flat, horizontal surface made of cast concrete. Steel-reinforced slabs, typically between 100 and 500 mm thick, are most often used to construct floors and ceilings, while thinner mud slabs may be used for exterior paving.

Knock Out CMU – Bond Beam 200mm

Bond beams are courses of block constructed with special units designed to receive horizontal reinforcement and grout. These units are used to integrate the horizontal reinforcement with vertical reinforcement bars in a reinforced masonry wall. Bond beams often are placed at regular intervals in the wall to permit placement of more reinforcement than would be possible using bed joint reinforcement.

3.1.2 Construction Method for CMU

Mortared Construction

1. Mortared Construction

2. Dry-Stacked Construction

Most

masonry

The alternative to mortared construction

mortared

is dry-stacked construction, where unit

concrete

construction

is

construction,

i.e.,

are

are placed without any mortar, then

bonded together with mortar.

both surfaces of the wall coated with

Varying

joint

surface

bonding

pattern of a concrete masonry

ground

units

wall can create a wide variety

elevations.

of

bonding coating provides excellent rain

the

interesting

bond

and

units or

attractive

appearance.

Dry-Stacked Construction

In

are

material. used

addition,

Shims

to the

or

maintain surface

penetration resistance.

Bond Pattern In addition, the strength of the masonry can be influenced by the bond pattern. The most traditional bond pattern for concrete masonry is running bond, where vertical head joints are offset by half the unit length.

Besides that, the most popular bond pattern with concrete masonry units is

stack

bond.

Although

stack

bond

typically

refers

to masonry

constructed so that the head joints are vertically aligned, it is defined as

masonry laid such that the head joints in successive course are horizontally offset less than one quarter the unit length.

Running Bond

Stack Bond

3.1.3 Fabrication Process of CMU

CONCRETE BLOCK MATERIALS

SAND

STONE

The aggregates such as sand and crushed stone form the main structure of block.

CEMENT

The cement acts as the binder that holds the aggregates together and solidifies the block when it’s mixed with water.

PIGMENT

WATER

THE MANUFACTURING PROCESS Mixing > Molding > Curing > Cubing and Storing 1.Mixing - Required amount of aggregates is measured in weight batcher plant. They are dumped into a conveyor belt. Conveyor moves the materials to mixer where water is added as the aggregates and concrete are poured in. The water is also precisely controlled with electronic measuring system. Any additional admixture are then added, and the batch is mixed for 6 to 8 minutes.

2. M o l d i n g

- The concrete is move using conveyor belt to block machine which molds is set up for a specific type of concrete block. The concrete are fed into the molds at a measured flow rate, and the vibration time and force is accurately controlled. After proper compression and consolidation are attained, the block is removed out of the molds onto a flat steel pallet.

3.

Curing

- Steel low-pressure steam kiln to be heated. Generally, the rack of concrete block is pre-set in the kiln.

Steam is gradually introduced to the kiln, and the temperature is slowly increased to the appropriate level. Shut off heat and steam when maximum temperature is reached, and soak blocks for 12 to 18 hours in the hot, moist air. Then moist air is exhausted out of the kiln where temperature increase to dry the block. Cures for 16-24 hours at high humidity and an average temperature.

4.

Cubing

and

Storing

- Curing process completed, block is rolled out of the kiln. Each block is then unstacked Pallets are the shifts to an automated stacker which placed them into and placed on a chain conveyor. Blocks are then move on to cubing system which stacks the blocks on a wood pallet by aligning and stacking to form a cube 4 blocks across by 3 blocks high. The cube is wrapped in plastic for security and protection from the elements.

3.1.4 INSTALLATION PROCESS OF CMU

1

Determine the number of blocks

6

Continue to lay the concrete blocks

2

3

Prepare the cement mortar

Spread the mortar along the corner

7

8

Check the alignment

Apply mortar on the top

4

Set the corner block

9

Stack the blocks

5

Apply Mortar to the side

10

Add reinforcement

3.2 STRIP FOUNDATION The purpose of this type of foundation is based on the distribution of the load of the above-ground structures (walls). It is designed to create direct resistance to soil movements, i.e. to prevent the building from sinking into loose soils or moving along its axes in any direction when the soil deforms around or directly under the house. A strip foundation can withstand enormous loads. It means that it is possible to build both lightweight structures and heavy houses on it. This type of foundation is also much more cost-efficient and easier to install than other foundation types.

A most elaborate and robust solution for reinforcing the foundation is that of building a whole reinforcement steel cage for the beam, with four longitudinal bars in the concrete and smaller diameter steel bars bent transversally to the longitudinal bars, spaced around 30 cm. The concrete must always contain and cover the rebars, so that it protects them from rusting while remaining near the corner of the concrete section, to resist bending.

3.3 PRECAST HOLLOW CORE SLAB A hollow core slab is a precast slab of prestressed concrete typically used in the construction of floors in multi-story apartment buildings. The slab has been especially popular in countries where the emphasis of home construction has been on precast concrete. Precast concrete popularity is linked with low-seismic zones and more economical constructions because of fast building assembly, lower self weight etc. Precast hollow-core elements is also known as the most sustainable floor/roof system and has far smaller CO2 footprint than even CLT slabs.

The precast concrete slab has tubular voids extending the full length of the slab, typically with a diameter equal to the 2/3-3/4 the thickness of the slab. This makes the slab much lighter than a massive solid concrete floor slab of equal thickness or strength. The reduced weight also lowers material and transportation costs. The slabs are typically 120 cm wide with standard thicknesses normally between 15 cm and 50 cm. Reinforcing steel wire rope provides bending resistance.

3.4 PRECAST STAIRCASE

To speed up site production, stair flights can be of precast instead of cast in-situ concrete. Precast stairs produces better surface finishes, avoids the inherent problems of casting complicated inclined sections on site and provides rapid access to successive floors. They are particularly cost effective when the design of the building requires a reasonable amount of repetition.

Typically two flights of stairs will be used at each story; the half landing may be cast integrally with the stair units or may be a separate slab, depending on the configuration of the supporting frame. The soffits and sides of the units may be specified to have a finish suitable for direct painting. (Alternatively units may be cast on their side, to give a good finish on both the upper surface and the soffit.)

3.5 LIGHTWEIGHT STEEL ROOF TRUSS

These lightweight steel trusses are fabricated from galvanized steel strips that have been rolled into shapes to add strength. They are commonly used in residential and commercial construction.

Photo 1 shows these trusses being set in place to support the roof of a veterinary clinic. Photo 2 shows these trusses in place to support the roof of a school building. Photo 3 shows the end view of a bundle of trusses. Note that the crosssection of a top or bottom chord has eight 90° bends as well as several other bends, which give these truss members great rigidity when compared to the flat strip of steel from which they were formed. Photo 4 shows the end view of trusses by another manufacturer.

O4 Precedent Study 4.1 Precedent Study 1 4.2 Precedent Study 2

4.0 PRECEDENT STUDY 4.1 PRECEDENT STUDY LIANYUAN

1

RETREAT

FIRM JYC Architect + DCD Associates TYPE Residential › Private House STATUS Built

Located at the foot of Dagan Mountain, just outside Alian Village, Lianyuan Retreat is on a longitudinal site surrounded by farmland. The main building has a huge setback from the street and a forest of trees, with a garage and servant quarters between the house and the main road.

The building was designed in a rectangular shape with a courtyard in the middle. As a traditional three-sided courtyard house, Lianyuan enjoys daylight and breezes associated with its shape. An outdoor fireplace in the courtyard acts as a visual focal point and the hearth of the household.

A double-skin design with concrete as the main structure and CMU blocks as outer layer throughout the entire house set the tone of the estate. A linear reflecting pond runs alongside the open side of the courtyard mediating the rough CMU block surfaces and the farmland. The balance between the private enclosure and the openness of the land is regulated by the modules of the CMU blocks that form solid, lattice, and punctured opening walls at various locations around the house.

IBS Factor

YEAR 2016 SIZE 3000 sqft - 5000 sqft

Type of Building Components Blockwork Components

Precast Components

Concrete Masonry Block (CMU)

Precast Column Precast Beam Hollow Core Concrete

Blockwork Components

IBS Factor

Analysis

Structural: Precast Column & Beam Precast Concrete Slab

1.0

Full IBS Factor

Wall: CMU Blockwork System

0.5

Partially IBS Factor

4.2 PRECEDENT STUDY

2

Located in the most populous city of Brazil, this long and narrow home in SĂŁo Paulo was redesigned to create more space. In a city where the value of land is getting ever higher, the design of this home by Terra e Tuma Arquitetos Associados does not discount the value of creating more open spaces infused with greenery.

MIPIDU HOUSE, BRAZIL ARCHITECT

A key feature revolves around the inclusion of two inner courtyards which function as outside spaces to provide lighter and ventilation while gracing the home with views of greenery. This matches to the overall design concept beautifully with most surfaces finished in raw concrete.

Terra e Tuma Arquitetos Associados TYPE House

With the living and other common areas re-laid out to the first floor, the bedrooms are then repositioned to the ground floor to maximize their views of the interior courtyards. The combination of raw finishes combined with the garden like views create a home that not only feels distinctly modern yet beautifully livable.

STATUS Built YEAR 2015 SIZE

Type of Building Components

170m²

Blockwork Components Concrete Masonry Block (CMU)

IBS Factor Blockwork Components

IBS Factor

Analysis

Structural: Precast Column & Beam Precast Concrete Slab

1.0

Full IBS Factor

Wall: CMU Blockwork System

0.5

Partially IBS Factor

Precast Components Precast Concrete Staircase Precast Column Precast Beam Hollow Core Concrete

O5 Technical Drawings 5.1 Architectural Plans

5.1.1 Ground Floor Plan 5.1.2 First Floor Plan 5.1.3 Second Floor Plan 5.1.4 Roof Plan 5.2 Elevations 5.2.1 North Elevation 5.2.2 East Elevation 5.2.3 South Elevation 5.2.4 West Elevation 5.3 Sections 5.3.1 Section A-A’ 5.3.2 Section B-B’ 5.4 Structural Plan 5.4.1 Foundation Plan 5.4.2 Roof Structure Plan

5.1.1 Ground Floor Plan Scale 1:100

up

an 5 .51. .12. 2F iFrisr ts tF lFol o ro rP lPal n 10 00 S cSac lael e1 :11: 0

up

5.1.2 Second Floor Plan Scale 1:100

23֯

23֯

23֯

23֯

23֯

23֯

37 ֯ 37 ֯

37 ֯

37 ֯

37 ֯

23֯

5.1.4 Roof Plan Scale 1:100

23֯

5.2.1 North Elevation Scale 1:100

5.2.2 East Elevation Scale 1:100

5.2.3 South Elevation Scale 1:100

5.2.3 South Elevation Scale 1:100

5 . 3 . 1 S e c t i o n A-A’ Scale 1:100

5.3.2 Section B-B’ Scale 1:100

5.4.1 Foundation Plan Scale 1:100

1

2

3

4

5

6

7

8

9 10

11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

A B C D E F G H I J K L

M N O P

5.4.2 Roof Structure Plan Scale 1:200

11

O6 Schedule of IBS Component 6.1 Concrete Masonry Unit Block 6.2 Precast Hollow Core Slab 6.3 Prefabricated Door

6.4 Precast Lintel 6.5 Prefabricated Window 6.6 Toilet Pod 6.7 Precast Staircase 6.8 Steel Roof Truss

06

CONSTRUCTION SCHEDULE

6.1 Concrete Masonry Unit Block Components

Walls B1

B2

200

Beams

Columns

B3

C1

200

200

200

400

200

200

200

200

Dimensions

200

400

400

06

CONSTRUCTION SCHEDULE

6.2 Precast Hollow Core Slab Schedule Hollow Core Slab

Components

HCS2

HCS1

Dimensions

200

200

900

900

06

CONSTRUCTION SCHEDULE

6.3 Prefabricated Doors

Flush door (main door)

12

Flush door

84

Sliding door

12

06

CONSTRUCTION SCHEDULE 6.4 Precast Lintel Lintel

Components

L3

L2

L1

200 200

Dimensions

Quantity

200

12

84

12

Lintel

Components L4

L5

200 200

Dimensions

Quantity

48

12

CONSTRUCTION SCHEDULE 6.5 Prefabricated Window Windows

Components W1

W2

Casement window

Awning window

900

2000

Dimensions

900

3300

12

48

Quantity

6.6 Toilet pod Components

Toilet pod TP1

1700

Quantity

TP2

1600

Dimensions

2600

06

12

3300

12

CONSTRUCTION SCHEDULE

6.7 Precast Staircase Components

Precast Concrete Staircase S1

4000

3200

1000

200

Dimensions

4100

06

1500

1500

1500

Quantity

2

1500

06

CONSTRUCTION SCHEDULE

6.8 Steel Roof Truss Steel trusses

Components

ST2

2500

3000

ST1

Dimensions

6800

Quantity

5000

12

48

06

CONSTRUCTION SCHEDULE

6.8 Steel Roof Truss Steel trusses

Components ST3

ST4

Dimensions

12700

Quantity

26

5600

18

O7 Construction Details 7.1 Wall to Foundation Connection 7.2 Wall and Beam Connection 7.3 Wall to Slab Connection 7.4 Wall to Column Connection 7.5 Wall to Wall Connection 7.6 Window to Wall Connection 7.7 Door to Wall Connection 7.8 Precast Staircase 7.9 Prefabricated Lightweight Steel Roof Construction 7.10 Lightweight Steel Roof to Beam and Wall Connection

WALL TO FOUNDATION CONNECTION

200

Concrete floor slab ( cast in situ ) NGL

Bond block may be used here concrete / mortar infill sloped inside

Cores filled with 15MPa concrete

200

7.1

600

7.2

WALL TO BEAM CONNECTION

Vertical reinforcement for closedend concrete masonry units can be set after wall has been laid

Knock-out CMU bond beam

Horizontal reinforcement placed in bond beams as wall is laid up

Standard CMU with cross webs knocked out at bond beam course

Metal lath, mesh, or wire screen placed in mortar joints under knockout bond beam courses to prevent filling of ungrouted cells

View block webs out

of standard before cross are knocked

View of block after cross webs are knocked out to accommodate horizontal reinforcement

7.3

WALL TO SLAB CONNECTION

200

Knock out block

Concrete slab with projection bar cast into bond block beam

section

7.4

WALL TO COLUMN CONNECTION

Vertical steel

Concrete infill

Horizontal steel in bond beams

CMU stiffener / column

The hollow core of full blocks are infilled with concrete and reinforced with steel bar to form a stiffener

CMU Full Block & Bond Beam when reinforced and infilled with concrete, becomes a stiffener & bond beam to replace conventional column, beam & lintel.

7.5

WALL TO WALL CONNECTION

Wall corner connection 400

200

COURSE 1

COURSE 2

200mm wall : 400mm horizontal module 200

Wall to wall intersection

200

Metal strap 3mm thick x30mm wide every second course

Mesh supporting concrete in core above or cores filled solid

Cores of unites filled with 15MPa concrete 200

COURSE 1

COURSE 2

7.6

WINDOW TO WALL CONNECTION

Sash groove

Sealant

Lintel reinforcement

Lintel To suit

Sealant

Plaste r Lugs to frame turned down into core filled with 15MPa concrete

Sill to suit

Sash block

Sash block

7.7

DOOR TO WALL CONNECTION

Min 150mm

Lintel should be installed with a minimum end bearing of 150mm, bedded on mortar levelled along its length and across its width

Min 150mm

Lugs to frame turned down into core filled with 15MPa concrete

Finished floor level

200

35

762 832

35

PRECAST CONCRETE 7.8 Precast Concrete Stairs

STAIRCASE Precast concrete staircase to first hollow core slab connection

Type of staircase : U-shaped staircase Storey height : 4000mm Tread width : 250mm Rise: 167mm Run: 250mm Landing: 1000mm

Support ledge welded to precast stair flight

Tooled joint

Precast concrete flight

Precast stair flight

Supporting hollow core

Fill core at support

Precast concrete staircase to foundation connection

Dowels into Grout tubes

Insitu R.C landing

Levelling shims

7.9

PREDABRICATED LIGHTWEIGHT STEEL ROOF CONSTRUCTION

Gusset plates Purlins

Top cord

Bottom cord

Gusset plates

Truss

7.10

LIGHTWEIGHT STEEL ROOF TO BEAM & WALL CONNECTION

C-channel roof truss Steel bolt Angel steel plate

Roof truss

Reinforcement bar Block as beam

Connector

Embedded truss anchor

Retrofit roof /truss tie attached to bond beam with masonry screws Hurricane gusset angle attached to bond beam with masonry screws

Moisture barrier Mesh to support concrete infilling Bond beam

O8 Construction Sequence

8.0 CONSTRUCTION SEQUENCE PLACING UNITS 1. The Foundation Before building the block wall. The foundation must be level, and clean so that mortar will properly adhere. It must also be reasonably level. The foundation should be free of ice, dirt, oil, mud, and other substance that would reduce bond.

2. Laying Out The Wall Taking measurements from the foundation or floor plan and transferring those measurements to the foundation, footing, or floor slab is the first step in laying out the wall.

Once two points of a measurement are established, corner to corner, a chalk line is marked on the surface of the foundation to establish the line to which the face of the block will be laid. Since a chalk line can be washed away by rain, a grease crayon, line paint, nail or screwdriver can mark the surface for key points along the chalk line, and a chalk line re-snapped along these key points. After the entire surface is marked for locations of walls, openings, and control joints, a final check of all measurements should be made.

3. The Dry Run- Stringing Out The First Course Starting with the corners, the Manson lays the first course without any mortar so a visual check can be made between the dimensions on the floor or foundation plan and how the first course fits the plan. During this dry layout, concrete blocks will be strung along the entire width and length od the foundation, floor slab, even across openings. This will show the mason how bond will be maintained above the opening. It is helpful to have 3/8 in. (10mm) wide pieces of wood to place between block as they are laid dry, to simulate the mortar joints.

4. Laying The Corner Units Building the corners is the most precise job facing the mason as corners will guide the construction of the rest of the wall. A corner pole can make this job easier. A corner pole is any type of post which can be braced into true vertical position and which will hold a taut mason’s line without bending.

Corner poles for concrete block walls should be marked every 4 or 8 in (102 to 203mm), depending on the course height, and the marks on both poles must be aligned such that the mason’s line is level between them.

8.0 CONSTRUCTION SEQUENCE 1

2

EXCAVATION

Setting up of the building could not less than 1.5m approximately from the plot boundary line.

3

STRIP FOUNDATION

Strip foundation based on the excavation.

is arranged layout after

GROUND BEAM

A foundation wall built from the concrete strip foundation to the height of placement of hollow core slab. Besides, reinforcement bars is done to the footing to make it stronger.

8.0 CONSTRUCTION SEQUENCE

4

5

6

Block laying

SLAB INSTALLATION

COLUMNS

WALL INSTALLATION

Ground floor slab is cast on site

After hollow core slabs are installed, it attached by reinforcement bars the filling with sand-cement grout.

After the floor slabs are installed, the block walls are then built on the strip foundation.

8.0 CONSTRUCTION SEQUENCE 8

7

9

TOILET POD

LINTEL & BEAM

DOORS AND WINDOWS

Other than that, the toilet pods are then lifted using crane and placed into the exact location.

The lintels are placed above all the doors and window openings.

In addition, beams acted as integral part of the wall, continue placed on top of lintels.

The doors and windows are placed and installed in the building.

8.0 CONSTRUCTION SEQUENCE

11

10

12

FIRST FLOOR SLABS

REPEAT THE SAME PROCEDURE

STAIRCASE

First floor hollow core slab is placed mounted in beam, the reinforced bars are blended into hollow core slab to secure placement of slabs.

The same process is repeated for the first and second floor subsequently.

The precast concrete staircases is lifted and installed in the building.

8.0 CONSTRUCTION SEQUENCE

13

14

ROOF TRUSSES

Steel roof structure is installed onto the beams, which supported by c-channel and battens were installed on top of the trusses.

15

ROOFING

FINISHES

Metal roof sheet and insulation is mounted on the roof trusses.

Floor finishes and dry wall are installed.

O9 IBS Score Calculation

9.0 IBS SCORE Elements

Area (m²) or Length (m)

IBS Factor

Coverage

IBS Score

Part 1: Structural System Ground Floor Load bearing blocks column and beam system with precast concrete floor slab

513.8m²

0.8

0.23

9.2

First Floor Load bearing blocks column and beam system with precast concrete floor slab

513.8m²

0.8

0.23

9.2

Second Floor Load bearing blocks column and beam system with precast concrete floor slab

513.8m²

0.8

0.23

9.2

Roof Roof truss with prefabricated metal roof truss

513.8m²

1.0

0.31

15.5

1.0

43.1

Total for Part 1

2281.4m²

Part 2: Wall System Exterior CMU Blockwork System

345.6m

0.5

0.51

5.1

Interior Drywall System

337.2m

1.0

0.49

9.8

1.0

14.9

Beam: 100% comply with MS 1064 part 10

100

4

Column: 100% comply with MS 1064 part 10

100

4

Walls: 100% comply with MS 1064 part 10

100

4

Slabs: 100% comply with MS 1064 part 10

100

4

54

2

Repetition of floor to floor height: =100%

100

2

Vertical repetition of structural floor layout =100%

100

2

Horizontal repetition of structural floor layout =100%

100

2

Prefabrication Staircase: 100% comply with MS 1064 part 10

100

2

Total for Part 2

682.8m

Part 3: Other Simplified Construction Solutions

Doors & Windows: 54% comply with MS 1064 part 10

Total for Part 3

26

Total Score

84

10 Conclusion

10.0 CONCLUSION

This assignment has taught us a lot about the blockwork system. We get to explore more about the blockworks, data, details and the drawing which related to the construction of the building but not just about the blockwork.

Through this assignment we understood about the Industrialized Building System.

For

examples,

the

type

of

IBS,

the

advantages

and

disadvantages of IBS. Based on the system we were assigned. we can understand more about the blockwork system. Like how do we consider when selecting blocks and how do we construct it when we choose it to use in building construction which is CMU. Other than that, we also learned about how the block are arranged and the dimension of each type of blocks and how do it construct perfectly by different type of construction method.

In conclusion the IBS system are to help the construction to construct in a better way by the result of less construction time, cost savings, higher

quality and better finishes.

11 References

11.0 REFERENCES 1. EDP Sciences. (2014). Retrieved 28 September 2020, from https://www.matec-

conferences.org/articles/matecconf/pdf/2014/01/matecconf_bust2013_01002.pdf 2. UKEssays. (November 2018). The Definition Of Industrialised Building System Construction Essay. Retrieved from https://www.ukessays.com/essays/construction/the-definition-of-industrialised-building-system-construction-essay.php?vref=1 3. https://pdfslide.net/documents/advantages-and-disadvantages-of-industrialised-building-system-ibs.html 4. Franco, J. (2018). Concrete Blocks in Architecture: How to Build With This Modular and Low-Cost Material. Retrieved 28 September 2020, from https://www.archdaily.com/889657/concrete-blocks-in-architecture-how-to-build-with-this-modular-and-low-cost-material 5. Li, L. (2018). Lianyuan Retreat. Retrieved 28 September 2020, from https://www.portfoliomagsg.com/article/lianyuan-retreat.html 6. ArchDaily. (2020). Mipibu House / Terra e Tuma Arquitetos Associados. Retrieved 28 September 2020, from https://www.archdaily.com/790794/mipibuhouse-terra-e-tuma?ad_source=search&ad_medium=search_result_all 7. Lianyuan Retreat. Retrieved 28 September 2020, from https://architizer.com/projects/lianyuan-retreat/ 8. Types of shallow foundations and their characteristics I Geotech d.o.o. I. Retrieved 28 September 2020, from https://www.geotech.hr/en/types-ofshallow-foundations/ 9. CMU Manufacturing Process | Nitterhouse Masonry. Retrieved 28 September 2020, from https://www.nitterhousemasonry.com/ourprocess/#:~:text=When%20curing%20is%20complete%2C%20the,deep%20and%20six%20blocks%20high 10. Master, W. (2018). Best Method of Block Work For Construction – Method Statement HQ. Retrieved 28 September 2020, from https://methodstatementhq.com/masonry-block-work-installation-method-of-statement.html 11. Brunetti, G. (2016). How to build a reinforced concrete strip foundation - Archivolumes. Retrieved 28 September 2020, from https://sites.google.com/site/archivolumes/how-to-build-a-reinforced-concrete-continuous-foundation 12. Concrete Block (CMU) Sizes, Shapes, and Finishes. (2019). Retrieved 28 September 2020, from https://www.archtoolbox.com/materialssystems/masonry/concblocksizes.html 13. NCMA. (2001). FLOOR AND ROOF CONNECTIONS TO CONCRETE MASONRY WALLS - NCMA. Retrieved 28 September 2020, from https://ncma.org/resource/floor-and-roof-connections-to-concrete-masonry-walls/

14. DGCA. (2020). DGCA Construction. Retrieved 28 September 2020, from https://www.facebook.com/DGCAconstruction/posts/chb-layingrunning-bond-vsstack-bond-pros-and-consdgcaconstruction/2668635943265740/ 15. How to Lay Concrete Blocks. (2020). Retrieved 28 September 2020, from https://www.wikihow.com/Lay-Concrete-Blocks