t ec h n i c a l ta l k -...

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B Y: I r. N g K o k P e n g

C h i e f E x e c u t i v e O f f i c e r

E a s t e r n P r e t e c h ( M a l a y s i a ) S d n . B h d .

n g . k p @ e p m s b . c o m . m y

T E C H N I C A L TA L K

P R E C A S T C O N C R E T E F O R B U I L D I N G -

a h o l i s t i c a p p r o a c h

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Agenda for Today

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P A R T 1

I n t r o d u c t i o n t o p r e c a s t c o n c r e t e s y s t e m

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Precast Concrete is Common in the World

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Some jobs in Malaysia constructed in Precast Concrete

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Pre IBS Era

Contractor Driven

Today

Government + Consultant +

Contractor Driven

• Mostly foreign Japanese and international contractors

• Utilisation of IBS is common in their countries

• Understands IBS and its key success factors

• Almost 100% jobs from private sector

• Government Agenda – IBS Score

• Private Sector – Driven by project needs (i.e. long span, time)

• Jobs obtained – balanced between government & private sector

Our experience in the Malaysian market since 1989

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Some problems and “complaints” on precast system..

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E N D O F P A R T 1

I n t r o d u c t i o n t o p r e c a s t c o n c r e t e s y s t e m

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P A R T 2

A P P R O A C H 1 – D e s i g n C o n c e p t

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Our holistic approach in Precast Concrete System in Malaysia

1. Concept

2. Precast Products

3. Design of Elements

1. Site Conditions

2. Erection of Elements

3. Safety

4. Speed of Erection

1. Production Planning

2. Productivity

3. Transport

Design

Production

Operation

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Application in Building - Precast Concrete is a System….

Unbraced Skeletal Frame System • Precast Columns • Precast Beams • Precast Slabs • Unbraced • Rigid Joint

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Braced Skeletal Frame System • Precast Columns • Precast Beams • Precast Slabs • Precast Walls (Stabilising Structure) • Pinned Joint

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Wall Frame System • Precast Walls • Precast Beams • Precast Slabs

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Combination of systems incorporating precast element, i.e.:- • Precast slabs with insitu columns & beams • Precast slabs & precast beams on insitu

columns • Precast slabs on steel structure • Precast slabs on masonry units

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Understanding what is available in the market is important

HOLLOW CORE SLABS

PLANKS

COLUMNS

WALLS

STAIRS

BEAMS

UNIT BATHROOMS

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Understanding each precast products is equally important..

Hollow Core Slabs • Types of hollow core slabs available

in the market • Load/Design chart • Characteristics of hollow core slabs • Advantages of hollow core slabs • Do’s and dont’s of hollow core slabs

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Understanding each precast products is equally important..

Examples • Understanding the process to manufacture

hollow core slabs • Avoid extra processes that will add to cost

(see Part 3) • E.g. notches in hollow core slabs • Take advantage of prestressing

• Economies of scales • Modular • High repetition

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Lets simplicity & common sense guide your design concept

Step 1 – Determine Column Location

Important Design Consideration:- 1. Installation 2. Connections 3. Stability and compliance to codes of practice 4. Local construction practices

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Step 2 – Framing of Precast Beams Important Design Consideration:-

1. Installation 2. RC or prestressed beams 3. Connections 4. Stability and compliance to codes of practice 5. Local construction practices

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Step 3 – Framing of Precast Slabs Important Design Consideration:-

1. Type of Slabs, wet areas 2. Installation 3. Connections 4. Stability and compliance to codes of practice 5. Local construction practices

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Which connection details to use?

Interaction and collaboration with precast concrete specialists is important. • Pinned / Fixed Connection • Transfer of Forces • Compliance to Codes and best practices

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E N D O F P A R T 2

A P P R O A C H 1 – D e s i g n C o n c e p t

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P A R T 3

A P P R O A C H 2 – P r o d u c t i o n M e t h o d

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Design

Production

Operation


1. Concept

2. Precast Products


1. Site Conditions


3. Safety



2. Productivity

3. Transport

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Considerations

Certifications & Credentials

Capacity & Loading Chart

Distance

• Can supplier do the job? • Open yard or sheltered? • Prestressing and/or RC? • Batching Plant • QA/QC • Know-how & Experience

• Capacity to undertake job? • Back-up plans? • On-going jobs?

• Distance from factory to site? • Method of transporting?

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Understanding Production Methodology enhances better decision making

Preparation Casting Delivery

1. Raw Material 2. Moulds 3. Production Schedule 4. Transport

Arrangement

1. Fitting of Moulds 2. Rebar Works 3. Concreting 4. Finishing

1. Storage Management

2. Coordination at Site

Stringent QA/QC Processes

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Automation Provides Consistency and Superior Quality

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Leading Precast Plant • Automated • Large storage areas • State-of-the-art computerised batching

plant • Long-line prestressing facilities • Heat and steam curing • Precast Information System (ERP)

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Advanced Production Facilities

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Stockyard

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Do not forget about safety

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Understanding Method of Transportation

Considerations • Size of precast

components • Loading & Unloading • Day or night delivery • Number of trips

required • Route to site (height

limitation, etc.) • Condition of internal

access • Unloading area at

site

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The future of pre-fabrication

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E N D O F P A R T 3

A P P R O A C H 2 – P r o d u c t i o n M e t h o d

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P A R T 4

A P P R O A C H 3 – O p e r a t i o n s

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Design

Production

Operation


1. Concept

2. Precast Products


1. Site Conditions


3. Safety



2. Productivity

3. Transport

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Understanding what is lead time

AWARD

DESIGN & APPROVAL

IBS FABRICATION

FOUNDATION WORKS

GROUND FLOOR

IBS INSTALLATION

M&E & ARCH. FINISHES*

BUILDING COMPLETION

MONTH 1-3 MONTH 4-6 MONTH 7-15*

LEAD TIME LEAD TIME

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Sequence of Works

APRIL

MAY

Considerations • Take full advantage

of unpropped design, i.e. M&E / Building Works to start concurrently.

• Floor-by-floor • Pyramid • Zone by zone • Critical Zones • Starting point and

finishing point

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Cranes

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Cranes

Considerations • Types of cranes • Number of cranes • Weight of precast

components • Crane coverage • Crane capacity • Crane Access / Path • Lorries Access • Closing of Access /

Demob of cranes

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Collaboration between ALL stake holders is important

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Planning is the KEY

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Associated cast insitu works to precast area

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Integration with other trades…

Considerations • Avoid duplication of plant/machineries • Optimisation of cranes • Early cut-off of design of M&E and other

trades

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How Eastern Pretech does it…..

And… PROJECT DEPARTMENT -Works schedule and sequence

-Site logistic

-Site coordination

-Customer complain

STOCKYARD DEPARTMENT

-To plan element to be deliver as per order.

-To make sure the finishing of elements meet requirement

DESIGN DEPARTMENT

-Construction drawing

-Elements shopdrawing

-Technical/design advice

PRODUCTION DEPARTMENT

-Production schedule/planning

-To plan mould and material require

-QA/QC

Led by a dedicated project personnel to coordinate

ERP System

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E N D O F P A R T 4

A P P R O A C H 3 – P r e c a s t S i t e O p e r a t i o n

S U M M A R Y

r e c a p

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Summary

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Summary

Design

Production

Operation

• Design to be as simple as possible • Avoid too much customisation • Think MODULAR & REPETITION

• Visit precast factories to understand producton methodologies

• The lesser the process, the cheaper it is

• Think OPTIMISATION

• Understand availability of cranes

• Optimise cranes • Think PRACTICALITY

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Summary

OPTIMISATON MODULAR & REPETITION

PRACTICALITY COST SAVINGS

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T H A N K Y O U

v i s i t u s a t

w w w . e p m s b . c o m . m y

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