DEVELOPMENT OF MASON RY MODULAR PRODUCTION … · DEVELOPMENT OF MASON Massetto, Leonardo Tolaine...

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Florianópolis

DEVELOPMENT OF MASON

Massetto, Leonardo TolaineTauil, Carlos Alberto

1 MSc, Civil Engineer2 PhD, Professor, São Paulo University

3 Architect Carlos Alberto Tauil, [email protected] Comercial Manager, Glasser P

To increase concrete hollow blocks concrete block industry launched in São Paulo market a Modular ProductionNonloadbearing Walls (for partition and exteriornamed SVM (Modular Masonry System(blocks, mortar and accessories), construction design technical support. As differentials, the company building schedule (agreed on contract), and the agreed price. This new pin São Paulo, Brazil, where the industrytechnology. This paper presents all aspects related to product development (quality manuals, project guidelines, building procedures, product development and R&D), management and commercial development (partnership shaping, commercial strategies, managemenprocedures), plus the building phases and control (workforce training, technological selection, management and production control).Conclusions demonstrate the economic viability of this building system. raised awareness about concrete block masonry performance characteristicslargely used as nonloadbearing walls. Keywords: CMU manufacturer, masonry innovation, construction system 1 INTRODUCTION Building construction in Brazil, including agents:

· the compatibility project (when designed· planning and monitoring services

(from the construction company· materials purchase (blocks, mortar, other materials)

company supply department,

15th International Brick and Block Masonry Conference

Florianópolis – Brazil – 2012

DEVELOPMENT OF MASONRY MODULAR PRODUCTION SYSTEM

Massetto, Leonardo Tolaine1; Sabbatini, Fernando Henrique2; Tauil, Carlos Alberto3; Guimarães, Mário Sergio4

MSc, Civil Engineer, [email protected]

São Paulo University, Civil Engineering Department, [email protected]

Architect Carlos Alberto Tauil, [email protected]

Comercial Manager, Glasser Pisos e Pré-Moldados, [email protected]

blocks sales and profits, in the early 2000`s, a major Brazilian concrete block industry launched in São Paulo market a Modular Production

partition and exterior walls). This technological innovation was Masonry System, in portuguese) and combine all materials

construction workforce, tools and equipments As differentials, the company ensure structural performance,

schedule (agreed on contract), and the agreed price. This new product was developed industry conducted more than 50 building sites

This paper presents all aspects related to product development (quality manuals, project guidelines, building procedures, product development and R&D), management and commercial development (partnership shaping, commercial strategies, managemenprocedures), plus the building phases and control (workforce training, technological selection, management and production control). Conclusions demonstrate the economic viability of this building system. The system also

ock masonry performance characteristics, since it remains bearing walls.

CMU manufacturer, masonry innovation, construction system

including nonloadbearing masonry, is divided among several

when designed), is done by a specialized company;services are responsibility of the construction site

from the construction company); (blocks, mortar, other materials) is done by the construction

department, and are acquired from different manufacturers;

N SYSTEM

;

, [email protected]

a major Brazilian System for

. This technological innovation was all materials supply

supply, and ensure structural performance,

roduct was developed building sites with this

This paper presents all aspects related to product development (quality manuals, project guidelines, building procedures, product development and R&D), management and commercial development (partnership shaping, commercial strategies, management procedures), plus the building phases and control (workforce training, technological selection,

The system also since it remains

divided among several

company; construction site engineer

construction from different manufacturers;

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Florianópolis

· the construction is responsibility of a

technical staff; · tools and equipment supply

company.

In this configuration the responsibilities responsible are rarely identified. Invariably the construction company pay for schedule increases, costs andconstruction companies:

· Excessive materials loss:(construction company) and those who use

· Low workforce productivity:who constantly adjusts the pace of the the responsibility of the concan cause delays; lack of planningwith other services (shafts, coat

· Low quality execution: there is deficient training; high labor errors reflect in cost and schedule

The brazilian building and construction sector went through a crisis in the 1990s. Figure 1 illustrates numbers related to formal jobs in the construction sectormetropolitan area. Notice that since 1997formal jobs in civil construction. The market remained retracted construction sector began a strong growth process.

Figure 1: Number of formal employMetropolitan Area

Given the late 1990`s recession shown Paulo metropolitan area was facing difficulties

· Retracted market (offer greater than demand· Commoditized product (fixed price· High quality and priced product;· Can`t make the market "realize" · Direct competition with low-· Culture of using ceramic blocks for



is responsibility of a workforce contractor, which doesn't have

supply is carried out by both the contractor and the construction

responsibilities are diluted and, if there are problems, those responsible are rarely identified. Invariably the construction company assumes the errors and

and quality loss. Below are the main problems faced by

Excessive materials loss: there are no links between those who purchase ) and those who use (contractor);

productivity: planning is responsibility of the construction companypace of the various services; often the material handling

construction company, and if this service is badlyof planning: large amount of reworks because of

with other services (shafts, coatings, etc.); there is little commitment of the contractor

labor turnover; informality; and impunity since the cost and schedule increases for the construction company.

construction sector went through a crisis in the 1990s. Figure 1 numbers related to formal jobs in the construction sector, registered in

that since 1997 there was a significant decrease in the generation of . The market remained retracted until 2005, when the

strong growth process.

ormal employees in construction industry in São Paulo Metropolitan Area (SEADE, 2011)

shown above, the concrete blocks market leader infacing difficulties:

greater than demand); Commoditized product (fixed price, market regulated);

product; Can`t make the market "realize" the product value;

-quality blocks; ceramic blocks for nonloadbearing walls;

doesn't have trained

construction

and, if there are problems, those assumes the errors and

main problems faced by

who purchase

planning is responsibility of the construction company, material handling is

badly managed interference

of the contractor to quality; since the contractor

construction sector went through a crisis in the 1990s. Figure 1 in São Paulo

the generation of when the civil

o Paulo

leader in the São

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· Construction companies with high

nonloadbearing walls. Within this outlook, the company developed the innovative production system by aggregating the materials and services supply, taking responsibility and ensuring all aspects related to masonry produced. The system was marketed as a and with guarantees provided by contractcomplete project development, the company built a partnership with Professor Fernando Henrique Sabbatini.

Figure 2: SVM (Sistema de Vedação Modular

The innovation in question was called SVM (Sistema de Vedação Modular Masonry System), and its development allowensured high profit levels. The purpose of this paper is to present list the stage of development, and illustrate the works where this technological innovation was used. 2 MODULAR MASONRY SYSTEMThe SVM component materials are:

· Concrete nonloadbearing hollow b· Mortars for block laying; · Reinforced mortar precast elements;· Accessories (hardware cloth /

fixation elements); · General materials (sand, cement, lime, additives, etc.)

To ensure the masonry quality the first step was to establish a series of strategic partnerships with all suppliers, ensuring favorable business conditions. The partnership agreements also included development and adaptation stages



Construction companies with high incidence problems in quality and performance

, the company developed the innovative production system by aggregating , taking responsibility and ensuring all aspects related to

masonry produced. The system was marketed as a closed package deal through a single ageby contract. Figure 2 illustrates the system structure. To the

complete project development, the company built a partnership with Professor Fernando

Sistema de Vedação Modular) Structuration

ion in question was called SVM (Sistema de Vedação Modular

, and its development allowed great value increase to the product and

to present the characteristics of this Modular Masonrydevelopment, and illustrate the works where this technological innovation was

EM (SVM) are: hollow blocks (CMU);

recast elements; hardware cloth / metal lath /wire mesh for wall tie, anchors,

General materials (sand, cement, lime, additives, etc.).

the first step was to establish a series of strategic partnerships ensuring favorable business conditions. The partnership agreements also

development and adaptation stages for new products, materials or technologies

problems in quality and performance of

, the company developed the innovative production system by aggregating , taking responsibility and ensuring all aspects related to the

hrough a single agent structure. To the

complete project development, the company built a partnership with Professor Fernando

ion in question was called SVM (Sistema de Vedação Modular - Modular to the product and

Masonry System, development, and illustrate the works where this technological innovation was

anchors, pins and

the first step was to establish a series of strategic partnerships ensuring favorable business conditions. The partnership agreements also

technologies.

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2.1 BLOCKS (A NEW FAMILY) Within the idea of production rationalization andperformance, the SVM starting point was the development system offers solutions that cover every situation with construction details number of components, simplifying the Following the international trend and respecting the module is 10cm. The reference unit has (height). In width, the nominal dimensions To maintain the continuity of holes holes, the "tie" between rows is done in 1/3 andthere are 20cm (2/3) and 10cm (1/3) componentssub-divisible, generating 5cm (1/6) Additionally, to permit vertical modular blocks of 5cm and 10cm in height, both with 30cm components family for a 15cm nominal thickness

3/3 2/3 (30cm) (20cm) (10cm) (5cm)

Figure 3: 15cm Thickness In order to increase productivity, and most walls are built without mortar joint was defined as 0,3cm and the the fractions as 9,7cm and 19,7cm). block and a tie between walls example

a) b)Figure 4: a) 10cm Thickness Family b)

Family), c)



production rationalization and the search for the maximization of

starting point was the development of a new family of unitiesevery situation with construction details that use

number of components, simplifying the construction.

Following the international trend and respecting the modular coordination standardmodule is 10cm. The reference unit has the nominal dimensions of 30cm (length)

the nominal dimensions are 10cm, 15cm and 20cm.

holes in the rows superposition, and once the units have three "tie" between rows is done in 1/3 and 2/3, i.e., every 10cm or 20cm. Because of it

1/3) components. The 10cm (1/3) element was designed to be elements that allow horizontal modular adjustments.

modular adjustments were developed two modular channel 5cm and 10cm in height, both with 30cm nominal length. The Figure 3 shows the

nominal thickness.

1/3 1/6 10cm channel 5cm channel

(10cm) (5cm) (30cm h=10cm) (30cm h=5cm)15cm Thickness Components Family

In order to increase productivity, and because they are focused on nonloadbearingmortar on the vertical joints. For this reason, the typical

cm and the entire (3/3) piece real length was defined as 29.7cmcm). Figure 4 illustrates the components family

example.

b) c)Family b) Real dimensions of the entire block (15cm), c) 1/3 wall tie design example

the maximization of masonry of unities. The

that use a reduced

standard, the basic (length) and 20cm

and once the units have three Because of it,

designed to be adjustments.

e developed two modular channel / . The Figure 3 shows the

channel

(30cm h=5cm)

nonloadbearing masonry, the vertical joints. For this reason, the typical vertical

was defined as 29.7cm (and family, a typical

dimensions of the entire block (15cm

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Florianópolis

2.2 MORTARS Mortars for laying blocks have critical influence on must have features such as workability, water retention capacity, adequate strength, deformability, adhesion and durability. Choosing the best mortar depends not only on the type and composition, but also on the characteristics of masonry units (Sab Because it is a rationalized production system, it windustrialized, bagged and prepared near the necessity of characteristics standardizationeasiness, transportation speed and flexibility. For thiswith a major mortar supplier industryapplication technique, the mortar should bwas signed an agreement with São Paulodeveloped. In order to verify mortar quality parameters before each workwere performed, as shown in Figure 5.

Figure 5: Adhesion tests performed before construction works 2.3 PRECAST AND OTHER MAThe SVM also has a precast components bond beams and frames, compatible withprecast are made in an industry with and mortars, these materials are delivered palletized 6 illustrates the dimensions of a modular frame, a window lintel (or bond beam)

Figure 6: SVM Precast elements example



have critical influence on the functional performance of wallsmust have features such as workability, water retention capacity, adequate strength, deformability, adhesion and durability. Choosing the best mortar depends not only on the type

the characteristics of masonry units (Sabbatini, 1986).

rationalized production system, it was defined that the mortarprepared near the application site. This choice was based on the

characteristics standardization, minimizing control on the receipt, storagespeed and flexibility. For this purpose, a partnership was

industry. To determine the optimal mortar ratio, the mortar should be carefully measured to ensure enough plasticity),

São Paulo University where were special mortars

In order to verify mortar quality parameters before each work start, adhesion testsshown in Figure 5.

tests performed before construction works

PRECAST AND OTHER MATERIALS components family made of reinforced mortar, used as lintels

, compatible with the walls modulation. To ensure product quality amade in an industry with controlled ratio, molding and curing. Just as the b

delivered palletized directly in the building sites. The Figure modular adjustment element for doors, a precast

frame, a window lintel (or bond beam) before and after application.

SVM Precast elements example

of walls. They must have features such as workability, water retention capacity, adequate strength, deformability, adhesion and durability. Choosing the best mortar depends not only on the type

batini, 1986).

as defined that the mortars would be . This choice was based on the

control on the receipt, storage a partnership was established

ratio (for bag to ensure enough plasticity),

special mortars were

tests (prisms)

of reinforced mortar, used as lintels, To ensure product quality all

, molding and curing. Just as the blocks . The Figure

precast window

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Florianópolis

2.4 WORKFORCE A key aspect of the SVM success workforce. Because it´s a development of a rationalizfor the first works a partnership contract was system became consolidated, the company expanded its also set up its own bricklayer’s team to ensure enable the continuous technologicalmortar application with the mortar productivity and the reduction of mortar

Figure 7: Utilization of technique of m The quality and productivity of the continuous training programs, conducted both in the company and in the different times (hiring, early works, 2.5 TOOLS AND EQUIPMENTSIn partnership with leading manufacturers, tools and equipment high productivity in the masonry constructiongeometry (30 cm and 3 holes). Block carts, mortar buggies, mortar tubslevels, squares, poles, etc. Figure 8 illustrates some of the equipment used.

Figure 8: Tools and equipments: special block carts, mortar buggies and horizontal axis mixer.



success is related to the high quality and productivity

rationalized system dependent on the workforce productivitycontract was signed with just one general contractor

, the company expanded its workforce partners. The company team to ensure process mastery, reduce labor turnover

technological development and improvement. Figure 7the mortar bag. The use of this tool can allow the

mortar consumption.

Utilization of technique of mortar bag application

The quality and productivity of the workforce services were based on extensive conducted both in the company and in the building sites

different times (hiring, early works, part-time).

TOOLS AND EQUIPMENTS manufacturers, tools and equipment were developed to ensure

construction. All development was directed to the blocks Block carts, mortar buggies, mortar tubs power mixers

Figure 8 illustrates some of the equipment used.

Tools and equipments: special block carts, mortar buggies and

horizontal axis mixer.

ity and productivity of the

productivity, general contractor. As the

partners. The company turnover and 7 illustrates

can allow the increase of

services were based on extensive and building sites at

were developed to ensure All development was directed to the blocks

power mixers, rules,

Tools and equipments: special block carts, mortar buggies and

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Florianópolis

2.6 PRODUCTION AND COMPAThe design stage is very important to ensure production design that conducts the work improvisations. The project is also a basis for planning the movements; blocks per floor, etc.). The project. The formal receipt of the finishedtolerances. A complete project manual was preparedany designer to make the masonry production 2.7 PLANNING AND MANAGEMENTFor each work carried out an overall planning serves as basis for pricmanagement is done based on the planning. Each work has a resident technical ensuring the work´s progress and quality. For each group of four works, there is a qualified technician, who manages strategically the The construction work is based on clear item). The controls are clear and objective, illustrates the design and construction manuals

Figure 9: Guidelines example for projects and procedures for 3 WARRANTIES By providing a complete package and concentratthe company is able to ensure several aspects such as:

· COST: The system is sold by packagefor the contractor. Any p



PRODUCTION AND COMPATIBILIZATION PROJECT The design stage is very important to ensure construction productivity and quality. It is the

the production, predicting any interference and avoiding

The project is also a basis for planning the building work (number of deliveries, materials ; blocks per floor, etc.). The building work supervision is also done based on the

finished services is based on the project and construction

prepared with all the system technical characteristics to allow production project.

PLANNING AND MANAGEMENT carried out an overall construction planning of the building is done

serves as basis for price formation and contract formulation. The buildingplanning.

technical and a full time workforce commissioner, responsible for progress and quality. For each group of four works, there is a qualified

ally the services.

is based on clear execution procedures (procedures are a ). The controls are clear and objective, done by building technical workers

construction manuals.

xample for projects and procedures for construction works

and concentrating materials and services on a single agent, the company is able to ensure several aspects such as:

The system is sold by package (extended price). This means the price is fixed production failure or variation is the contractor

productivity and quality. It is the and avoiding

work (number of deliveries, materials work supervision is also done based on the

project and construction

with all the system technical characteristics to allow

of the building is done. This . The building

commissioner, responsible for progress and quality. For each group of four works, there is a qualified

(procedures are a contract ers. Figure 9

construction works

materials and services on a single agent,

the price is fixed contractor sole

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responsibility. For exampleconsumption, costs are entirely

· DEADLINE: Along with construction work the construction schedule (prepared by bothpart ensures compliance with thesubject to penalty. On the other hand, changes in modifications, equipment breakdownin penalties for the contracting company;

· QUALITY: The quality parameters (quality of – construction tolerances) are contractually formalized. All services must be performed according to the project (and planning) and in case of nonexecution failure all costs are

· PERFORMANCE: AlthougSVM is sold with a structural performance guarantee (in Brazilwere lots of pathologies related to masonry caused by originated in excessive deformation in related to masonry, as fissures,

4 DEVELOPMENT STAGES Because it`s an important technological innovation, until its marketing consolidation on a commercial scale. Initially development was performed, defining the materials, design criteria, procedures and partnerships build up. In(including 27 construction works) scale. A summary of the development Early technological development initial development for the first constructions

· Development of family blocks· Development of the project manual· Partnerships with material suppliers· University agreement; · Construction work procedures· Partnerships with workforce contractors

Implementation of 3 prototype scale the building of three sites with different characteristicsduring the development. Although being aschedules and the performance guarantees have also been applied.

· Consolidation of the projects m· Verification of tolerances and quality criteria



responsibility. For example: in case of blocks breaking or mortar are entirely funded by the contracted company;

construction work prices, deadlines, terms and conditions, schedule (prepared by both parts) is a contract part. The contract

compliance with the implementation period laid down, andsubject to penalty. On the other hand, changes in building work conditions (such as

, equipment breakdown and the non liberation of work frontsthe contracting company;

: The quality parameters (quality of applied materials and finisheds) are contractually formalized. All services must be

performed according to the project (and planning) and in case of non-compliance or failure all costs are under the responsibility of the contracted part

Although it is a system focused on nonloadbearingis sold with a structural performance guarantee (in Brazil, in early 1990, there

were lots of pathologies related to masonry caused by unexpected excessive deformation in reinforced concrete structures). Any problem

fissures, is covered by formal guarantee.

important technological innovation, SVM was developed in 3 macroconsolidation on a commercial scale. Initially the whole technology

, defining the materials, design criteria, construction work build up. In total there were 44 months of development

works) until the marketing of the first works on a commercial evelopment stages is shown below:

development - this step was carried out in 7 months and included the constructions on a prototype scale.

ocks; of the project manual;

with material suppliers;

Construction work procedures development; workforce contractors.

3 prototype scale constructions - this step took 13 months and included with different characteristics, in order to verify hypothes

during the development. Although being a prototype, all works had "real" budgets and schedules and the performance guarantees have also been applied.

Consolidation of the projects manual and construction procedures olerances and quality criteria

mortar excessive

terms and conditions, The contracted and delays are

conditions (such as fronts) can result

finished services s) are contractually formalized. All services must be

compliance or part;

focused on nonloadbearing masonry, in early 1990, there

unexpected endeavors Any problem

macro-steps whole technology construction work

44 months of development on a commercial

months and included the

13 months and included in order to verify hypothesis achieved

real" budgets and

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· Partnerships with new material suppliers· Development of their own workforce team· Early development of budget and· Training development · Sales team (SVM sales) training and development

Implementation of 24 pilot scale constructionsmonths. It included the accomplishconstruction parameters were made,sale have different characteristics from

· Consolidation of the project · Consolidation of partnerships· Consolidation of commercial

5 CONSTRUCTIONS / RESULTSDuring the development phase constructions builders. Figure 10 illustrates some works

Figure 10: D



with new material suppliers their own workforce teams

budget and marketing procedures

training and development

constructions - this was a consolidation stage and accomplishment of 24 works where the final adjustments in

, in addition to the commercial aspects development (sale have different characteristics from products sales).

project manual and construction procedures; artnerships (suppliers and workforce contractors); ommercial procedures and team.

CONSTRUCTIONS / RESULTS constructions were done through contracts with

illustrates some works done in the prototype-pilot phase.

Different building types examples

this was a consolidation stage and last 28 final adjustments in the

the commercial aspects development (SVM

ith different

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The works had distinct characteristics: size of the construction site, differences in vertical transport (cranes, lift), constructionThese characteristics were important parameters. 6 FINAL CONSIDERATIONS SVM established itself as an important nonloadbearing walls in São Paulo. The performance, cost and time of the builders, that recognized the value sales increase and ensure the company's profit The concrete blocks superior performance also share of the concrete block in constructiona market once dominated by ceramic It`s possible to say that SVM establishedtechniques), disseminating good practices that were "copied" and in the building technology currently Nowadays, because of industry operational characteristics increase of loadbearing masonry salessuspended. 7 REFERENCES SEADE – Fundação Sistema Estadual de Análise de Dados. Informação dos Municípios Paulistas – IMP. < http://www.seade.gov.br/produtos/imp/ Sabbatini, F. H. ”Argamassas de assentamento para paredes de alvenaria1986. 29p. (Boletim Técnico BT 02/86)



The works had distinct characteristics: size of the construction site, differences in vertical construction scale, number of towers per building site, schedules.

These characteristics were important to define the budget, planning and construction

important technological innovation in the São Paulo. The performance, cost and time guarantee meet the

recognized the value added to the services package offered and allowed and ensure the company's profit margin during a crisis time.

superior performance also allowed to significantly improve constructions with nonloadbearing masonry, increasing

ceramic nonloadbearing blocks.

established a technological benchmark (for materialtechniques), disseminating good practices that were "copied" and ended up being incorporated

currently in use.

industry operational characteristics and market changesof loadbearing masonry sales), the commercialization of SVM was

Fundação Sistema Estadual de Análise de Dados. Informação dos Municípios http://www.seade.gov.br/produtos/imp/>. Maio, 2011.

Argamassas de assentamento para paredes de alvenaria”. São Paulo,. (Boletim Técnico BT 02/86)

The works had distinct characteristics: size of the construction site, differences in vertical , schedules. construction

in the market for meet the desire

offered and allowed

significantly improve the market increasing sales in

materials and incorporated

changes (strong temporarily

Fundação Sistema Estadual de Análise de Dados. Informação dos Municípios

São Paulo, EPUSP,

DEVELOPMENT OF MASON RY MODULAR PRODUCTION … · DEVELOPMENT OF MASON Massetto, Leonardo Tolaine...

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