Report Writing

BEL 422 REPORT WRITINGAP224 (2A)

1.0 INTRODUCTION

The construction industry is one of the most dynamic, risky, challenging and rewarding

fields. It involves numerous uncertainties and widely associated with a high degree of risk

due to the nature of construction business activities, processes, environment and

organization (N.A. and S.A., Kartam, 2001).

Based on the report by CIDB (2000), it also underlines the contributions from the

construction sector are more than just economic, the products of construction whether

directly or indirectly through provision of superior infrastructure and buildings has contributed

extensively towards the creation of wealth and quality of life of the population. The activities

generated from the construction activities will in turn generate the productivity of other

industries, resulting in a well-balance economy in our country.

“The school infrastructure development plans will be reviewed to ensure that the

educational system in the country is more holistic as is the case in developed countries. The

review of the schools' design could result in cost savings of between 20 and 30 per cent and

the money saved can be utilised for infrastructure development for the students and

teachers," said Deputy Prime Minister Tan Sri Muhyiddin Yassin (News Sraits Time

2010/01/07).

The Industrialized Building Systems (IBS) has the known theoretical advantages of

speed, safety and quality. However, in Malaysia, wet construction method is still widely

accepted as a convention and safe option despite incurring higher cost and slow production

rate (ICCBT 2008).

From the statements above, this report will review the best the most efficient method of

construction that can reduce cost and completion time spend due to school infrastructure

such as hall, classes and teacher’s room.

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2.0 CONSTRUCTION

2.1 Introduction

Construction’s method these days is known as Modern Method Construction (MMC).

MMC consists of two parts which are Industrialised Building System (IBS) and non-

Industrialised Building System (non-IBS).

2.2 Industrialised Building System (IBS)

Fully prefabrication or namely Industrialised Building System (IBS) stated by

Construction Industrial Development Board (CIDB) as construction system which

components are manufactured in a factory, on or off site, positioned and assembled into

structures with minimal additional site work. IBS can be done in two ways, those are off-site

and on-site fabrication.

Offsite fabrication is the description of the spectrum or part there of which are

manufactured assembled remote from building site prior to installation in their find position.

Whereas all Offsite may be regarded as falling within a generic IBS heading, not all IBS may

be regarded as offsite (Gibb and Pendleton, 2006). Consists of Offsite Construction (OSC),

Offsite Manufacturing (OSM) and Offsite Production (OSP) is largely interchangeable terms

that refer to that part of the construction process that is carried out away from the building

site, such as in a factory or sometimes in specially created temporary production facilities

close to the construction site (or field factories) (Goodier and Gibb, 2006).

Pre-fabrication is a manufacturing process generally taking place at a specialised

facility, in which various material are joined to form a components part of final installation

(Tatum et al, 1986). Pre-assembly carried on a definition as a process by which various

material, pre-fabricated components and or equipment are joined together at a remote

location for subsequent installation as a sub unit. It generally focused on system. Therefore,

a generic classification of IBS term in this report is based on the following assumption

(ARCOM Conference 2009).

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Figure 2.2.1: Generic classification in MMS

2.3 Construction using IBS

2.3.1 Low cost construction

→ Site clearance to the chosen space

Figure 2.3.1.1: Site clearance

→ Excavate pit to receive footing (size varies to varies project). Each footing must be on

the same level to provide a stable base. Footing then concreted.

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Modern Method of Construction

(MMS)

Assembly on site

Non-Industrialised

Building System

On-Site Fabrication

Industrialised Building System

Off-site Manufacturing (OSM),

Prefabrication, Offsite Fabrication (OSF),

Offsite Production (OSP)

Pre-assembly at Factory


Figure 2.3.1.2: Excavate pit

Column attached to the footing.

Figure 2.3.1.3: Attachment of the column

→ Initial wall set to the column after cross bar fix through the column.

Figure 2.3.1.4: The wall is set to the column

→ Another cross bar fix by drilling to bind the wall to the column.

Figure 2.3.1.5: The crossbar is fixed to combine the wall and the column

→ Wall to receive window and door been set and bind by the cross bar.

Figure 2.3.1.6: The wall is fixed to receive doors and windows

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→ Fix the ventilation wall.

Figure 2.3.1.7: The ventilation wall is fixed

→ Roof frame fixed to the column and beam.

Figure 2.3.1.8: The roof frame is fixed to the column and beam

→ Installation of roof coverings including gutter and rainwater drop pipe, electric services

and appliances.

Figure 2.3.1.9: The instalment of the roof coverings

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→ Slab concreted.

Figure 2.3.1.10: The slab is concreted

→ Finishes works and site cleaning.

Figure 2.3.1.11: Finishes work and site cleaning

→ Construction done and pass to the client.

Figure 2.3.1.12: The construction work is done

2.3.2 High cost construction process is same with low cost except:

→ Shuffle and distribution works for stump bases. Each stump bases that already

coordinated is concreted to avoid it from moving.

Figure 2.3.2.1: Shuffle and distribution works for stump bases

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2.4 Non-Industrialised Building System

Non-Industrialised Building System or also known as wet construction method.

Normally for school building, in-situ materials are used. Material involves consists of

concrete (mixed of cement, aggregates, sand and admixtures), reinforcement (high tensile

and mild steel) either bar or fabric, bricks and etc. Divided into elemental works of

construction such as foundation, building frame, wall, roof, building services and appliances,

electrical and mechanical works and others.

2.5 Construction using non-IBS

Foundation

→ Excavation and ground breaking including grading the lot and getting it tested for

compaction, digging trenches for footings and setting batter boards to level the house.

In this situation, footing either typed strip or pit.

→ Formwork set to the side and soffit of the foundation. All necessary support work such

as plunking and strutting must be done.

→ Reinforcement bar laid on the lean concrete inside the space provide by formwork or

mould.

→ Concrete poured to the foundation and vibrated to ensure it compacted. Initial curing

duration for the concrete is seven days.

→ Dismantle the formwork and defect works for foundation applied if necessary.

Figure 2.5.1: Slab reinforcement with wire mesh

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Ground beam

→ Excavate trench to receive ground beam.

→ Pour lean concrete to the ground to create a proper base for the beam.

→ Formwork is set to the site and soffit of the beam.

Figure 2.5.2: Section of ground beam

→ Lay reinforcement to the ground.

→ Pour concrete into provided space.

→ Curing duration is required before dismantle the formwork.

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Figure 2.5.3: Formwork is set to the site and soffit of the beam

Column

→ Reinforcement bars is connected to the starting bars from the foundation and across

the ground beam bars.

→ Set formwork to side and soffit of the column. Supported works to the formwork is

required.

→ Pour concrete to the formwork and vibrated to compact the concrete.

→ Formwork is dismantled after the column’s concrete dry and able to carry its load.

Slab

→ Excavate to receive slab.

→ Necessary works to create a proper and firm base to receive the slab is required. The

base is provided varies to the nature of soil.

→ Pour lean concrete to the ground to cover the base (hardcore) and to receive damp

proof membrane (DPM).

→ DPM lay to the lean bases horizontally while damp proof course (DPC) vertically.

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Figure 2.5.4: Section of the slab

→ Pour an inch of concrete to the DPM and DPC.

→ Place the reinforcement onto the concrete base and pour the concrete again until

required level / height.

→ Concrete slab is left to let it harden and able to carry / receive loads in several days,

depending on the weather.

Wall

→ Laying bricks from one end until reach the other end of the wall. Put a level on top of

the bricks to make sure they are even. Repeat the process on the face of the bricks to

make sure none are protruding.

→ Use mortar in between the bricks to make sure the bricks settle properly. Make sure

the mortar is laid properly so they don't jut.

→ Cut a brick in half, lengthwise, to begin and end every alternating layer. This will give

added foundation to wall.

→ Continue laying the bricks until you reach the top of the foundation wall. In between

placing layers, always use the level to check if the edges are straight and the lines are

even.

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Figure 2.5.5: Method of laying bricks

→ Inspect the mortar joints after installing five rows. If the joints were getting dry, hit them

with a joiner. Every 1 m², tie the bricks using exmet.

→ Spike metal ties into the studs of the wall. Turn the metal ties on the top of the brick.

This binds the brick wall to the attaching wall.

→ Opening for door and window been made during the construction of wall.

Figure 2.5.6: Opening for doors and windows

Roof beam

→ Set the formwork above wall (perimeter) using all necessary support work required

including scaffolding.

→ First part of concrete laid inside the formwork.

→ Placed reinforcement bar above the concrete and across the column’s reinforcement

and tied up.

→ Pour concrete to the required level and let it harden for several days.

→ Dismantle the formwork and clean the beam’s surface.

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Roof

→ Prepare wall plate to the perimeter of wall and fixed to the beam.

→ Ceiling joists set and fixed along wall plate with certain spaces / distances between

each ceiling joists.

Figure 2.5.7: The setting up of roof

→ Rafter set and fixed to each ceiling joist at certain degrees.

→ Ridge board set to connected the rafter at the rafter’s end (another rafter’s end been

fixed to the ceiling joists).

→ Hip and valley rafter fixed to the ridge and wall plate or ceiling joists (depend on its

suitability).

→ Permanent strut used to support the rafter where it fixed to the rafter and ceiling joist.

→ First layer of insulation paper lay and fixed to roof surface.

→ Wyre mesh placed above the insulation paper and tied to the roof structure.

Figure 2.5.8: Wyre mesh placed above the insulation paper and tied to the roof structure

→ Second part of insulation paper placed above the wyre mesh and tied to the roof

structure.

→ Roof tiles installed and fixed to the roof structure.

→ Apex, ridge and hip rafter tiles installed to the roof structure.

→ Fascia board installed to perimeter of the roof.

→ Gutter fixed to the fascia board.

→ All necessary piping works are installed including rain water down pipe to the roof

structure.

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2.6 Benefits of IBS

Although IBS is an advance system, but there are not perfected yet because based on

current technologies or methods, we still far from the perfection of the construction method.

Hence, the benefits of IBS are:

→ The repetitive use of system formwork made up steel, aluminium, etc and scaffolding

provides considerable cost savings (Bing et al. 2001).

→ Construction operation is not affected by adverse weather condition because

prefabricated component is done in a factory controlled environment (Peng, 1986).

→ Prefabrication takes place at a centralised factory, thus reducing labour requirement at

site. This is true especially when high degree of mechanisation involved (Warszawski,

1999).

→ An industrialised building system allows for faster construction time because casting of

precast element at factory and foundation work at site can occur simultaneously. This

provides earlier occupation of the building, thus reducing interest payment or capital

outlays (Peng, 1986).

→ An industrialised building system allows flexibility in architectural design in order to

minimise the monotony of repetitive facades (Warszawski, 1999).

→ An industrialised building system provides flexibility in the design of precast element as

well as in construction so that different systems may produce their own unique

prefabrication construction methods (Zaini, 2000).

→ An industrialised building system component produces higher quality of components

attainable through careful selection of materials, use of advanced technology and strict

quality assurance control (Din, 1984).

2.7 Benefit of non-IBS

Non-IBS method more focuses on the quality of the structure itself. This quality is

important for the durability, strength and other criteria that must exist together with the

structure. The benefit of non-IBS includes:

→ Flexibility in forming shape in various design, more or less monolithic and etc.

→ Grade of concrete used can be adjusted in site due to site condition. Usually occurs in

several elements such as piling and foundation.

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→ Work done orderly by stages because of continuously in forming the elements,

especially for the building operatives. Every stage is connected. Hence, the element is

very cohesive in bond within each other.

→ It is a common method of construction used in Malaysia and wisely said that almost

every contractor can accomplish construction by doing this method.

→ Building can be extended in future. Nowadays, it is a common thing to extend the

building.

→ Looking where this method already used for a long time previously, there have been

many records on time taken to its completion, material used, flow of work on each

element or section. These records are crucial and enabled similar project to be cost

easier while giving rooms to the contractor to predict the progress of the project costly.

→ Standardisation of this method made it easier to be adapt in order to fulfil the

requirement stated in the building regulation.

2.8 Comparison between IBS and non-IBS

Comparison between IBS and non-IBS will only explained in several criteria for this

report. Those criteria are completion time or duration of construction, manpower and

machinery required for work, material available, quality of work and environment of

construction site.

Criteria IBS Non-IBS

Duration IBS not affect by weather

condition because each part of

the element is made in factory.

It means there is no void in

waiting the concrete to dry.

Hence, less time required to

complete each work.

Concrete need at least 28 days to gain full

strength (fully dry). If the weather is

inconsistent, it may further the period for

concrete to gain full strength.

At least 7 days needed for concrete to able

withstand its and minimum loads, so the next

sequel of works must be after 7 days. These

contribute to the long period of construction

completion.

Manpower and

machinery

Less plant and labour required

for works because all parts of

structure are already made,

labour’s job is minimal such as

fixing the component of

Huge amount of labour and plant needed

(based on construction size) to perform the task.

Plant needed to carry and lift things, mixed the

concrete and etc.

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structure. Labours needed for almost each section of

works because works done manually (for

formwork, plastering and etc).

Material This method required custom

part of the structure. It means

only few supplier or contractor

are specialist for preparing the

part.

Availability of material is high. There are many

suppliers for material required by this method.

Quality All parts are prepared off site

(in factory) with maximum

control of quality. Quality of

parts easily standardise at

factory.

It is hard to maintain the quality of concrete due

to inconsistency of weather, concrete mix,

compaction and etc.

Environment Parts done off site, hence less

waste is created on site.

Less material on site brings it

environment to easily manage

and maintain its neatness.

Every works or parts done on site for this

method. It is almost impossible to perfectly

complete each part. There must be waste

produce by each work especially for concrete

work, preparing the formwork and others. These

pollute vision of the site and automatically

reduce its safety.

Raw material (cement, bricks, reinforcement

and etc) place on site is hard to maintain its

position / neatness.

3.0 RECOMMENDATION

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Recommendation for the school building consists of three (3) types which are store,

building for student and building for teacher.

3.1 Store

Store is used for keeping things. So the easiest way to prepare the store is using a

contenna. Usually contenna is used for temporary office at site, but here, it is modificated to

suit its function. By using a contenna as a store, the building itself can be transferred from

one place to another because it is not permanently installed at one place. Hence, it can be

moved when its current place to be used for other occasion. This modification covered:

→ Ventilation system use natural method where the contenna provided spaces for the

ventilation itself.

→ Contenna made by metals, so the temperature inside the store is high when the sun

rises. To overcome this situation, an insulation layer used to wrap certain part of the

building which can reduce the heat from sun.

→ Additional layer of floor to withstand the loads imposed from inside the building.

→ This building is constructed off site, so on site works only for preparing the base of the

building.

3.2 Building for student

When it comes to building for student, the loads imposed internally is high and

simultaneously. Things to be measured are the load imposed, safety, and maintenance

works, time taken for completion and cost. Hence, we decided to recommend building that

using partial IBS method and partial non-IBS method after accounting things to be measured

to it. Furthermore, these mix will produce huge amount of loads capability, ensure safety for

the building because it can withstand fire for a certain time, less maintenance, decrease

duration for its completion and most important is the cost which also be reduced from normal

method nowadays.

Construction processes of this mix method are:

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→ Site preparation and clearance done for selected site. This includes levelling works

(cut and fill if necessary), removing hedges, clearing undergrowth, removing trees and

stumps and excavating topsoil.

→ Excavate pit to receive foundation. Excavated materials remove from the site.

→ Set the formwork to sides and soffits of the foundation. Necessary support item such

as plunking and strutting are required.

→ Concrete blinding laid to the base to prepare a proper base.

→ Pour initial layer of concrete with thickness about 50mm.

→ Place reinforcement bar to the concreted layer of foundation.

→ Pour concrete until it reach the specific height required.

→ Dismantle the formwork after the foundation dry and able to withstand loads. Usually

takes seven days to dry, but can be reduced by using proper additional admixture.

→ Excavate trenches to receive ground beam and levelled the base of slab.

→ Formworks are set to the side and soffit of the beam.

→ Concrete blinding laid to all surface of ground beam and slab’s base.

→ Place damp proof membranes to surface of both beam and slab (DPM must be in

good condition and no tear available.

→ Pour the initial layer of concrete to the beam.

→ Place the enforcement bars onto the layer.

→ Pour concrete to reach the height of slab’s base while pour an initial layer of concrete

to the slab.

→ Place fabric reinforcement bar to slab and bind the beam’s bar to the slab’s bar.

→ Pour concrete until it reach specified level of slab.

→ Dismantle the formwork after concrete dry enough.

→ Set custom made formwork for the wall (column and wall are attached and fixed to

each other). This custom made formwork contain reinforcement link inside it in order to

omit the use of reinforcement bar and bricks. Formwork will not be dismantled because

it will become parts of the building itself and the material use is light weight concrete.

→ Pour concrete to the formwork until required height. Vibrator is used in all concrete

work to compact the wet concrete and make it denser.

→ This formwork provided along spaces or opening for doors and windows. Hence,

concrete must be poured by stages to suit the opening.

→ Roof frame structure made in factory by the manufacturer. The structure dissembles in

factory to ensure that it can be transport easily to the site. This frame is ready paint at

factory by the manufacturer.

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→ Roof frame are assemble at the site and fixed to the wall. Covering works for roof

structure done similar to the process of completing the construction of roof as shown in

the previous chapter.

→ All doors and windows are installed to the building.

→ Electrical works such as preparing the neutral spot (earthing process which buried

rods into the earth to balance the electricity), installing light, fan, sockets and all

necessary additional works done to the building.

→ All interior work including finishes and accessories done to the building.

3.3 Building for teacher

All the construction processes for this building are same with the process involved in

the student’s building. These two types of building only differ in its function (material used

inside also different such as teacher’ table and chair and the arrangements) while teacher’s

building have additional work which are mechanical work that involves in installing air-

conditioning goods.

3.4 Benefits of mix method

Mix method done in order to gain benefits that provided in both IBS and non-IBS

methods. Benefits of this mix method are:

Time to complete the construction of building is reduced because concrete works done

in large part or section.

Less labour required to complete the construction compare to non-IBS method.

Quality of the concrete works mostly constant due to continuous works of its kind.

Strength of the building increased due to the cohesiveness bond between each part or

section of building and material used for concreting.

Durability of the building increased due to the mixture of several parts in the building

(such as slab and ground beam combine and the combination of wall and columns).

Less cost for constructing the building based on the decrease of completion time,

labour needed and other factors as well.

Emphasize skills in construction technologies due to the collaboration between the

methods mentioned before.

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4.0 CONCLUSION

Each method in construction industries has its own strength and weakness. These

methods rely on each other to bury their own weakness and produce a higher level of

perfection when there are no perfect method existed ever. Perfection also has its own cost.

It’s also occurred to the mix method.

Mix method may seem as it’s flawless, but then again, nothing is perfect. The main

challenge that must be faced to construct by using this method most likely consists of:

Skills required by the contractors (which only few percentage of them has).

Experiences (a little amount of contractor, designer and client ever merged with this

method).

Construction regulation must be updated to enhance the method (standardisation

important to keep the quality of construction industries).

Suitability (the design of school building have been standardised for years, any

changes to the design must be followed by research and other process as well, just to

know whether the design can be used or not).

All this problem must be solved to enable changes of method can be used, and most

importantly can be done to the school’s building.

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5.0 REFERENCE

Books / journals

o Prab Bhatt, Thomas J. MacGinley & BS Choo, Reinforced Concrete ‘Design

theory and examples. Third edition published year 2006, Taylor & Francis.

Internet

o cidb.gov.my

o Frequently Asked Questions - Industrilised Building System (IBS) Official Portal

of CIDB Malaysia.mht

o http--www_building_co_uk-Pictures-thumb-Builder_Group-Building-

2002_issue_45-meteor_jpg.mht

o http--www_he-con_com_my-v2-images-home1_jpg.mht

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6.0 APPENDICES

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Report Writing

Documents

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