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SMART REINFORCINGBETTER • FASTER • CHEAPER

foreword

MITA (P) 269/06/2003

June 2016

Prefabrication Takes FlightTraditionally, welded wire mesh for slabs and walls can be used to fast track the steel fixing work for a project.

However, the conventional concept of welded wire mesh has limitations as the wire diameter is only upto 13mm with the closest spacing fixed at 100mm (area of steel 1328mm2/m).

To overcome this limitation and to allow prefabrication and use of slab mesh for slabs with heavy loading, we have incorporated single directional mesh upto 25 mm diameter bar in our product range (please refer to page 2 for more details). This allows mesh to be used for heavy slabs or raft foundations that previously can only be reinforced using loose bars.

Hence, these solutions can help builders fulfill BCA’s requirement of 65% prefabrication for slab.

By continuing our efforts to provide “Better, Faster, Cheaper” reinforcing solutions, BRC strives to support our valued customers as prefabrication takes flight.

Lim Siak Meng Group Managing Director

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42 Storey Residential Building at Robinson RoadSpecification of Mesh for SlabTo support regulatory requirements and to give designers more flexibility to cater to varied slab design requirements, BRC has the following F-mesh solutions for slab:

Bet

ter

Mesh Ref.

Main Bar/Wire Cross-Sectional Area Holding Wire Mass

Size mm Spacing mm Main mm2/m Size mm Spacing mm

kg/m2

F2510 25 100 4911 13 800 39.85F2512 25 125 3929 13 800 32.15F2515 25 150 3274 13 800 27.00F2517 25 175 2807 13 800 23.34F2520 25 200 2456 13 800 20.58

F2010 20 100 3143 13 800 25.98F2012 20 125 2515 13 800 21.05F2015 20 150 2096 13 800 17.76F2017 20 175 1796 13 800 15.40F2020 20 200 1572 13 800 13.64

F1610 16 100 2012 10 800 16.57F1612 16 125 1610 10 800 13.42F1615 16 150 1341 10 800 11.30F1617 16 175 1150 10 800 9.80F1620 16 200 1006 10 800 8.67

F1307 13 75 1771 8 800 14.40F1310 13 100 1328 8 800 10.91F1315 13 150 886 8 800 7.44F1320 13 200 664 8 800 5.70

F1210 12 100 1132 8 800 9.37F1215 12 150 755 8 800 6.41F1220 12 200 566 8 800 4.93

F1110 11 100 951 8 800 7.95F1115 11 150 634 8 800 5.47F1120 11 200 476 8 800 4.22

F1010 10 100 786 8 800 6.66F1015 10 150 524 8 800 4.61F1020 10 200 393 8 800 3.58

2F1310 2 x 13 100 2656 8 800 21.332F1315 2 x 13 150 1772 8 800 14.39

2F1210 2 x 12 100 2264 8 800 18.252F1215 2 x 12 150 1510 8 800 12.33

2F1110 2 x 11 100 1902 8 800 15.412F1115 2 x 11 150 1268 8 800 10.44

2F1010 2 x 10 100 1572 8 800 12.812F1015 2 x 10 150 1048 8 800 8.71

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42 Storey Residential Building at Robinson RoadSpecification of Mesh for SlabB

ette

r

F-mesh is a single directional mesh to cater for large spans, heavy slabs. Main rebar upto 40mm is available.

Holding wireMain bar/wire

a. Horizontal layer b. Add vertical layer.

c. Completed slab.

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42 Storey Residential Building at Robinson RoadFa

ster

Specification of Mesh for Slab

Main Wire Area Mass

Size mm (A)

Spacing mm (B)

mm2/m kg/m2

8 100 503 3.95

8 150 336 2.64

8 200 252 1.98

9 100 637 5.00

9 150 425 3.34

9 200 319 2.50

10 100 786 6.17

10 150 524 4.11

10 200 393 3.09

11 100 951 7.47

11 150 634 4.98

11 200 476 3.74

12 100 1132 8.89

12 150 755 5.93

12 200 566 4.44

13 100 1328 10.42

13 150 886 6.96

13 200 664 5.21

2 x 10 100 1572 12.34

2 x 10 150 1048 8.23

2 x 13 100 2656 20.85

2 x 13 150 1772 13.91

Cross Wire Area Mass

Size mm (C)

Spacing mm (D)

mm2/m kg/m2

8 50 1006 7.90

8 75 671 5.27

8 100 503 3.95

8 125 403 3.16

8 150 336 2.64

8 175 288 2.26

8 200 252 1.98

8 400 126 0.99

10 50 1572 12.34

10 75 1048 8.23

10 100 786 6.17

10 125 629 4.94

10 150 524 4.11

10 175 449 3.52

10 200 393 3.09

13 50 2656 20.85

13 75 1771 13.90

13 100 1328 10.42

13 125 1063 8.34

13 150 886 6.96

13 175 759 5.96

13 200 664 5.21

Nomenclature for specification: “H” AB CD Eg: H1315 1020 - Diameter 13 x 150 + Diameter 10 x 200

Mesh can be manufactured by combining main and cross wires to suit the varied design requirements for slab and wall as follows:

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42 Storey Residential Building at Robinson RoadFa

ster

• Household shelter wall specified in D10 mesh.• To improve productivity, 8 sheets of mesh were combined and supplied as 5 panels.• 2 workers took 20 minutes to install the 5 panels and another 2 hours to insert the loose U links.• Time improvement of at least 50% compared to original specification.

18 Storey Mixed Development at Tanjong Pagar - Prefab Household Shelter Wall

Original reinforcement details for household shelter wall

50% Time Improvement

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Light Industrial Building at Ayer Rajah - Raft Foundation Slab Mesh

1. Bottom vertical layer of T20-150 F-mesh.

• 800mm thick raft foundation slab.• Reinforcement - T20-150 bothways, top and bottom.• Total weight - 31 MT covering 500m2.• Single directional F-mesh was used to speed up steel fixing work. Che

aper

Original slab detail.

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Light Industrial Building at Ayer Rajah - Raft Foundation Slab Mesh

2. Top layer of F-mesh with bend to cater for slab edge.

• Each sheet of mesh weighed about 150kg.• 8 workers took 18 hours over 2 days to complete laying the mesh or 4.7 manhour/MT.• Tying loose bars will take at least 4 days.• Time savings of 2 days per cast.

3. Raft completed for casting.

Saved 2 Days

Che

aper

Saved 2

Days Per Cast

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5 Storey Industrial Building at Loyang - Prefab Beam

• Heavy prefab beam measuring 1.2m (W) x 0.6m (D) x 11m (L).• Reinforcement: 2 x 9 x T40 Top + 9 x T40 + 9 x T32 bottom, 2 x T10-200 links.• Total weight – 5 MT per beam.Bet

ter

1. Workers guiding the prefab beam into position.

Original beam detail.

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Slanted mesh for staircase wall.

5 Storey Industrial Building at Loyang - Prefab Beam

• 5 workers took 15 minutes to install the beam and another 2 hours to tie the loose lapping bars.• Tying loose bars will take at least 10 hours.• Time savings of 90%. Bet

ter

2. Putting concrete spacers before lowering the prefab beam into formwork

Original beam detail.

90% Time Savings

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• Precast beam for terrace factory.• Reinforcement for beam prefabed for quick drop in installation at the precast yard.• Each beam weighed between 0.9 MT to 2.5 MT depending on bar and link configuration.• Prefab beam formed by loose rebar welded to beam cages.

3 Storey Terrace Factory at Gul - Prefab/Precast Beam

Precast beam sectional and reinforcement details.

1. Prefab reinforcement for precast beams ready for delivery.

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• 2 workers took 30 minutes to fix the remaining loose links before hoisting the prefab beam into the mould for inspection and casting.• Fixing loose bars conventionally will take at least 4 hours.• Time savings of more than 80%.

3 Storey Terrace Factory at Gul - Prefab/Precast Beam

Precast beam sectional and reinforcement details.

2. Workers tying loose links to complete the prefab beam before casting at the precast yard.

80% Time Savings

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Fonda

• Post-tensioned slab in bays of 60m x 9m.• Bottom slab reinforcement: A8 mesh + T10-400.• Top slab reinforcement: A8 mesh, T10-200 loose bar.• Additional bottom reinforcement combined into engineered A8 mesh to raise site steel fixing productivity. • T10-200 top bars converted into mesh for easy laying.

8 Storey Warehouse at Tuas South - Engineered Mesh for Post-tensioned Slab

Original slab reinforcement detail.

Fast

er

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8 Storey Warehouse at Tuas South - Engineered Mesh for Post-tensioned Slab

1. Bottom A8 mesh combined with equivalent of T10-400 reinforcement.

Shop drawing for A8 mesh +T10-400(B) equivalent.

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Fonda8 Storey Warehouse at Tuas South - Engineered Mesh for Post-tensioned Slab

• For 1 bay, 30 sheets of mesh measuring 7m x 2.4m (500m2) were laid in 2 hours by 6 workers.• Original specifications of A8 + T10-400 will take at least 6 hours to complete.• Time savings of more than 60%.

2. 6 workers laying the mesh which were packed in sequence to avoid further searching or sorting on site.

3. Bottom mesh for 1 bay completed.

Sequential Packing

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8 Storey Warehouse at Tuas South - Engineered Mesh for Post-tensioned Slab

• Direct workers were used to lay the mesh.• Assuming all in labour cost of $12/hour, the cost of laying mesh is about $0.30 to $0.40/m2. If we add 60% idling time, the cost is still about $1/m2. • This is a huge saving from mesh laying sub-contracting rate of $3 to $5/m2.• 60% to 80% labour cost savings.

4. Workers laying T10-200 engineered mesh over post tensioned beam instead of loose bars.

5. 30 sheets of A8 top mesh (385m2) were completed in 2 hours by 6 workers.

80% Labour Cost

Savings

Upto

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Manufacturing CapabilitiesOver the pass two years, BRC has relentlessly upgraded our manufacturing capabilities and capacity for prefabricated reinforcement. Our upgraded arsenal consists of:

• Fully automatic mesh welding lines from Europe.

• Automatic double benders from USA, Europe.

• Automated shear lines for rebar cutting from USA, Europe.

• Automatic link benders from Europe and Japan.

BRC ASIA LIMITED

350 Jalan Boon LaySingapore 619530

Telephone enquiries 6265 2333 Fax 62664728

Visit our website at www.brc.com.sgOr email us at sales@brc.com.sg