Industrialized Building System 2012

Industrialized Building Systems

BUILDING SYSTEM CLASSIFICATION Structural System

Industrialised Building System (IBS)

(1) Conventional building systemTimber formwork

(2) Cast in-situ formwork System(a)Table form and (b)Tunnel form

(3) Prefabricated System(a)Precast concrete panel (b)Precast concrete frame (c)Precast steel frame

(4) Composite System- (1), (2) or (3)

Non Structural System Conventional

Non - Structural System- IBS

Brick & Plaster

Solid Block

Hollow Block

Interlock Block

Precast Panel

Precast Brick

Classification of Industrialised Building SystemFully prefabricated building system can be classified into two

main categories, namely

1. on-site prefabricated On-site precasting provides several

advantages over cast in-situ construction. These include mass production of units, cost and time reduction, improved quality of units, etc. prefabricated method involves casting structural building elements within site before erecting to actual location. Offsite prefabricated method involves transferring building operations from site to factory. Prefabrication allows a component to be built whenever convenient, so long as it is delivered on time.

2. off-site prefabricated (factory producing). On-site

Industrialised Building System (IBS) Crystal Palace, Hyde Park

During construction 1840

Picture taken in 1851

Classification of Industrialised Building SystemComposite building system involves casting some elements

in the factory while others are cast in site.Types of precast elements usually produced are floor slabs,

infilled wall, bathrooms, staircase, etc and are placed for incorporation into main units, column and beams, which are usually, cast in-situ.

Elements of Industrialised Building SystemGenerally, IBS components can be divided into five

broad categories which include (a) frame system, (50% or more IBS) (b) panel system, (50% or more IBS) (c) box system, (100% IBS) (d) formwork system, (50% or more IBS) (e) block system (50% or more IBS)

Industrialised Building System (IBS)

History of IBS in Malaysiaa) Concept IBS in Malaysia is not new b) In 1966 the two pilot project started by using IBS concept. Namely? i) Pekeliling Flat, Kuala Lumpur ii) The Rifle Range Flat, Penang c) In 1981-1993 PKNS acquired pre-cast concrete technology from Praton Haus International, Germany to built housing project

Industrialised Building System (IBS)

History of IBS in Malaysia

KLCC

Pekeliling Flats

LRT Station

KL Tower

Industrialised Building System (IBS)

Characteristics of IBS1.3.1 Five Characteristics of IBS are : a) Industrial production of components though prefabrication b) Reduced labour during prefabrication of components and site works c) Modern design and manufacturing method using CAD/CAM d) Systematic Quality Control i.e ISO 9000

Industrialised Building System (IBS)

The Current Scenario of Malaysian Construction Industry

This can contributes : Messy Sites, High Wastage, Labour Intensive, Low Quality and Delays

Industrialised Building System (IBS)

Benefitsa)Reduction of site labour b)Minimal Wastage c) Less site material d)Cleaner environment e)Controlled quality f) Neater and safer sites g)Faster project completion h)Lower total construction costs due to the above

Industrialised Building System (IBS)

Case Study

Parcel 5 & 6, Precinct 9 750 units (900 sqft) Durations : 18 months

Parcel 4, Precinct 9 520 units (1000 sqft) Durations : 18 months

Elements of Industrialised Building System

(a) frame system, (b) panel system, (c) box system, (d) formwork system, (e) block system

Frame System

Precast Frame System

Frame SystemFrame system consists of main structural element

columns, beams, frames or trusses made of plain concrete, prestressed concrete, or steel.Their important characteristics are the capacity to

transfer heavy loads over large spans.Therefore, they are often used in the construction of

industrial building, apartment, warehouses, sport facilities, and school.

Frame System

Frame System

THE STRUCTURAL SCHEME A multi-storey building includes the following structural components

Frame System

Elements of Frame System

Figure 2.2: Typical linear prefabricated elements: (a)-(d) beams; (e), (h) joists; (f), (g) girders; (i), (j) columns; (k), (l) footings (Allen, 1999)

Connection between ElementsConnection can be achieved through concrete grout which

is spread on a concrete bearing to provide a uniform load distribution over the connected surface. The grout normally between 20-30mm thick and consists of a 1:3 cement-tosand mix with a stiff consistency.

Connection can be achieved through the bearing pads,

consists of elastomeric materials (neoprene), laminated fabric, synthetic fibers, and other materials, which allow a certain degree of freedom of movement to supported members.

Bearing pad for bridge

Bearing PadThis pads permit a smooth and uniform transfer of load

from the beam to the substructure.This pads have no movable parts and thermal expansion

and contraction are absorbed by the pad.There is no sliding between pad and beam or between pad

and abutment.

Connection between ElementsConnection can be achieved through the steel plates and

angles. Steel plates are embedded into concrete elements during casting. Then steel plates between two concrete elements are either welded or bolted. These types of connection, however induce additional stress due to the nature of fixed connection.

Connection between ElementsTypical connection details are shown in Figure 2.3 and they are: Connection between column and cast in-situ footing uses a steel plate anchored to a column and bolted to bars in the footing, Figure 2.3(a). Connection between column and a precast footing, Figure 2.3(b). Connection for the bolted support between two columns, Figure 2.3(c).

Figure 2.3: Typical connections between frame elements: (a), (b) column to footing; (c) column to column; (d), (e) beam to column; (f) beam to girder

Connection between Elements

Connections [Figure 2.3 (d) and (e)] for the joint between

column and beam. Both elements are fixed together through a dowel sleeve entry or welding of steel fixtures. Furthermore, a corbel supported connection is preferred structurally and is mostly applied in industrial buildings.

Connection for the detail between main supporting beam

and girder, Figure 2.3(f).

Beam connections A projecting concrete haunch is cast on to the column

with a locating dowel or stud bolt to fix the beamA projecting metal corbel is fixed to the column and the

beam is bolted to the corbel

RECTANGULAR BEAMS Connections

There are three basic solutions: 1. bolted connections, 2. Projecting reinforcement 3. Pockets joint

4. 5.

In the bolted connection, the column base plate is fixed to the foundation bars with nuts. With projecting reinforcement, projecting bars from the foundation or from the column are fixed into grouted openings in the columns or in the foundation respectively. In the case of pockets, the column is fixed into the pocket with grout or concrete.

6.

CONNECTIONSPrecast columns are fixed to the foundations with pockets, projecting reinforcing bars or holding down bolts. The first solution is mainly used for foundations on good soil; the second and third in the case of foundation piles.

POCKET FOUNDATIONSPrecast pocket foundations realize the site-work faster and cheaper. Indeed, site-cast pockets need rather complex molding and reinforcement, and the working conditions are more unfavorable. The industry has developed a series of pocket foundations for different column sizes. The precast pocket foundations may only be used in conditions of firm and level ground. The pockets are positioned by means of leveling bolts. The baseplate is cast on site.

POCKET FOUNDATIONS

Column-to-column splices Column-to-column splices are made either by bolting mechanical connectorsanchored in the separate precast components or by the continuity of the reinforcement through a grouted joint.

Column connectionsThe main principle in constructing column connections is to ensure

continuity.

Dowel connection

For simple connection - dowel placed at the upper or lower column - If continuity of reinforcement is required the reinforcement from upper and lower column are welded or lapped before completing the connection with in situ concrete.

PRECAST CONCRETE COLUMN CONNECTIONSClick to edit Master text styles Second level Third level Fourth level Fifth level

BEAMS

PURLINSPurlins are used as secondary beams for roof structures with light roof cladding. The distance between the portal frames is maximum 12 to 16 m. The units are in prestressed concrete.

Purlins are mainly used in industrial storage buildings where light roof coverings such as steel sheet decking,corrugated slabs, cellular concrete slabs, etc. are used.

Purlins Connections

Advantages of Frame SystemThe advantages of frame system are as follows:They can be designed using prestressed method for

very large spans of up to 30m and used mostly in heavy industry buildings.Frame system elements such as columns provide

considerable flexibility in partitioning the layout into functional spaces compared to precast panels.

Disadvantages of Frame SystemThe disadvantages of frame system are as follows: Frame system are normally used for heavy industry buildings, hence considerable attention is required to design the connection and joint details. The transportation of large frame system limited by the countrys road safety requirement.

Panel System

Prefabricated Panel SystemsPanel systems are commonly used for floor slabs, partitions,

exterior walls, and interior wall.

Unlike frame systems, which are mainly used as structural

framing, panel systems can be used as non-loading bearing space enclosure functions.

They can also be prefabricated on-site or off-site

Elements of Panel SystemThere are many panel systems available in the market. These are room size : floor slab panels, modular hollow core floor slabs, tee or double tee prestressed beams, ribbed (cassette) floor slabs, interior walls, exterior walls, etc.

Room Size Floor Slab PanelsRoom size floor slab panels are suitable for typical room size

with 3.5-5m span.The structural thicknesses of room size slabs are 120 130mm

for 3 4m spans under a moderate load. However, thicknesses of 180-200mm are required for spans up

to 5.5m. The width of slabs can be up to 3.6m if transported horizontally and up to 4.0m if transported vertically.

Panel Systems

(a)room-size slabs on cross walls (b)modular slabs on cross walls (c)modular slabs on exterior walls (d)slabs on beams and column

Types of Precast Slab (panel)

Precast Flat Slab

Thicknesses of 4", 6" and 8" Spans up to 25-0" Standard panel width = 4-0"

Slab

Lattice Girder

Half Slab

Half Slab

Half Slab

(h) Storage and curing PHCS Hollow core floor slabs are can be used for span up to 15.0m with thickness of up to 300mm.

Hollow Core slabThicknesses of 4", 6", 8", 10" and 12"

Spans up to 40-0" Standard panel width = 4-0"

Hollow Core slab

Figure 2.8: Precast floor elements (a) double-tee (b) single tee; (c) cassette slab; (d) support detail

Panel Wall Systems

Plate 2.4: External precast concrete wall

Acotec Wall Panels (Panel System)

Acotec Wall Panels

Technical Highlights:1.One unit of 600mm x 3000mm panel (75mm & 100mm

thickness) is equivalent to 112 pieces of bricks.2.Total Wall Weight is reduced by approximately 45%. 3.The panel surface quality allows a skim coat finishing

for internal walls

Advantages of Acotec PanelsEarlier start The weather-resistant nature of concrete allows panels to be loaded out much earlier and installation to begin before the building envelope has been weathered

Advantages of Acotec PanelsFaster installation

Full-height partitions are installed in one operation; maximum height of blockwork to be laid in one day is 1.5 meters. Also, installation rates are significantly faster than masonry alternatives.

Advantages of Acotec PanelsLightweight construction

The lightweight nature of the finished partitions leads to savings in cost and time in the construction of building foundations and frames. These gains are made while retaining the solid concrete feel to finished partitions.

Advantages of Acotec PanelsDurability

The innate toughness of concrete in combination with a thin finish coat yields a very high level of durability. Water saturation whether by condensation, leaks or flood will have no deleterious long-term effect on the panels.

Water resistance

Advantages of Acotec PanelsEnvironment

With panels custom-made for each project and the small amounts of mortar and plaster required, waste is reduced to a minimum. Furthermore, the lightweight nature of the panels reduces the burden of transportation.In-use benefits of the wall systems are also significant

Wall Panel Installation

Box System

Precast Box System

Different arrangements of box system: (a) separate units; (b) checkerboard pattern; (c) framed units

Box SystemBox systems consist of concrete walls and floor slabs

that form together to act as structural building element. They can either be cast in box moulds or assembled in the plant from panel elements. Normally, box elements contain a substantial amount of finish works such as electrical wiring and conduits, painted, glazed doors and window frames, plumbing pipes and fixtures, and cupboards before transporting the module to an erection site.

Box Systems

Box Systems

Box Systems

Box system

Box System

System Formwork System

Formwork SystemsFormwork systems are also referred to as

industrialisation onsite where the structural elements consist of horizontal slabs supported on a series of parallel cross wall spaced at a equal interval.These walls and slabs are cast in-situ with steel or

aluminum mould forming them. The remaining interior and exterior walls are built conventionally or made of precast elements. The common type of formwork system are as follow.

Cast in-situ tunnel form method

Cast in-situ tunnel form system

Formwork Systems

The Cast in-situ Tunnel Form MethodTunnel form is a formwork system that allows the

contractor to cast walls and slabs in one operation on a daily cycle.

Tunnel Forms

Forms wall and slab together

By Anand (B Tech 1 , 2012)

Cast in-situ Table Form MethodCast in-situ table form method separates vertical form for

walls and horizontal table form for floor slabs. In addition, the two elements are cast in two separate operations.First, the wall forms are installed and cast, followed by

removal of the forms after setting. Then, the slab table forms are erected and positioned for further horizontal slab casting.

Cast in-situ table form system

Wall Form

Block / Modular System

Block SystemModular coordination or MC is a dimensional system. It

is a dimension and space coordination concept in which building and components are placed at their designations based on the unit or basic module known as "1M" that equals to 100 mm.

What is Interlocking block?

Interlocking Blocks is a Load Bearing Interlocking

Concrete Block Wall system.

This system is also similar to the LEGO blocks,

which we are more familiar with.

Modular System

Anchored Earth Wall

Anchored Earth Wall

Anchored Earth Wall (dowel bar connection)

Anchored Earth Wall

Concrete Masonry Unit (CMU) Construction

Concrete Masonry Unit (CMU) ConstructionMortar and Grout:a) Mortar - used to bond masonry products together.

Composed of portland cement, sand, lime and water.b) Grout - similar to mortar, except used as a filler,

especially for vertically-reinforced walls. Specified as either fine-grained or coarse-grained

Horizontal (Joint) CMU Wall ReinforcementPurposes:

To strengthen the wall against "bowing" in due to lateral pressure (earth, wind, seismic)

Horizontal (Joint) CMU Wall Reinforcement:

Shapes: ladder & truss Materials: Steel with various finishes and gaugesLadder

Truss

Vertical CMU Wall Reinforcement:Purpose - Greatly strengthen the wall to accommodate

larger vertical loads as well as resist lateral loads.Vertical CMU wall reinforcement consists of inserting

steel rebar into open cores of the wall, then filling those cores solid with a concrete-like grout

Vertical CMU Wall Reinforcement:

Cell Reinforcing

Thank You