Modernisation, Mechanisation and Industrialisation of Concrete Structures

Kim S. Elliott is a consultant to the precast industry in the UK and Malaysia. He was Senior Lecturer in the School of Civil Engineering at Nottingham University from 1987-2010, and was formerly at Trent Concrete Structures Ltd., one of the UK's leading precast concrete manufacturers. An active researcher into the behaviour of precast concrete structures, he has published extensively on the subject. He is a member of FIB Commission on Prefabrication. Zuhairi Abd. Hamid is Executive Director of the Construction Research Institute of Malaysia (CREAM). With more than 32 years of experience in the construction industry, his research interests and expertise falls within the area of Strategic Management of IT in Construction, Strategic Facilities Management in the Health Sector, Structural dynamics (wind engineering and earthquake engineering), prefabricated building construction and the Open Building System.

• About the Editors xiNotes on Contributors xiiiPreface xviiPart 1 Modernisation of Precast Concrete Structures 11 Historical and Chronological Development of Precast Concrete Structures 3Kim S. Elliott1.1 The five periods of development and optimisation 31.2 Developing years and the standardisation period 261.3 Optimisation and the lightweight period 341.3.1 Minimising beam and slab depths and structural zones 341.3.2 Orientation rule 381.3.3 Composite and continuous floor slabs 381.3.4 Composite and continuous internal beams 431.4 The thermal mass period 461.4.1 Background to fabric energy storage in precast framed and wall structures 461.4.2 Admittance and cooling capacity 481.4.3 Thermal resistance and U-values for precast ground and suspended floors 511.4.4 Conclusion to FES, cooling and thermal transmission 58References 592 Industrial Building Systems (IBS) Project Implementation 61Kim S. Elliott2.1 Introduction 612.1.1 Definition of IBS 632.1.2 Advantages of IBS 642.1.3 Sustainability of IBS 672.1.4 Drawbacks of IBS 682.2 Routes to IBS procurement 692.2.1 Definitions 692.2.2 Preliminaries 702.2.3 Project design stages 712.2.4 Design and detailing practice 792.2.5 Structural design calculations and project drawings 802.2.6 Component schedules and the engineer’s instructions to factory and site 872.3 Precast concrete IBS solution to seven-storey skeletal frame 892.4 Manufacture of precast concrete components and ancillaries 932.4.1 Requirements and potential for automation 932.4.2 Floor slabs by slip-forming and extrusion techniques 932.4.3 Comparisons of slip-forming and extrusion techniques, and r.c. slabs 1022.4.4 Hydraulic extruder 1022.4.5 Reinforced hollow core slabs 1032.4.6 Automated embedment machines for mesh and fabrics in double-tee slabs 1062.4.7 Optimised automation 1092.4.8 Table top wall panels 1102.4.9 Production of precast concrete wall panels using vertical circulation system 1152.4.10 Control of compaction of concrete 1182.4.11 Automation of rebar bending and wire-welded cages 1182.5 Minimum project sizes and component efficiency for IBS 1202.6 Design implications in construction matters 1202.7 Conclusions 122References 1243 Best Practice and Lessons Learned in IBS Design, Detailing and Construction 125Kim S. Elliott3.1 Increasing off-site fabrication 1253.2 Standardisation 1333.3 Self-compacting concrete for precast components 1373.4 Recycled precast concrete 1423.5 Building services 1443.6 Conclusions 147References 1474 Research and Development Towards the Optimisation of Precast Concrete Structures 149Kim S. Elliott and Zuhairi Abd. Hamid4.1 The research effort on precast concrete framed structures 1494.1.1 Main themes of innovation, optimisation and implementation 1494.1.2 Structural frame action and the role of connections 1514.1.3 Advancement and optimisation of precast elements 1564.1.4 Shear reduction of hcu on flexible supports 1574.1.5 Continuity of bending moments at interior supports 1594.1.6 Horizontal diaphragm action in hollow core floors without structural toppings 1604.2 Precast frame connections 1624.2.1 Background to the recent improvements in frame behaviour 1624.2.2 Moment-rotation of beam to column connections 1624.2.3 Research and development of precast beam-to-column connections 1674.2.4 Column effective length factors in semi-rigid frames 1704.3 Studies on structural integrity of precast frames and connections 1704.3.1 Derivation of catenary tie forces 170References 173Part 2 Mechanisation and Automation of the Production of Concrete Elements 1775 Building Information Modelling (BIM) and Software for the Design and Detailing of Precast Structures 179Thomas Leopoldseder and Susanne Schachinger5.1 Building information modelling (BIM) 1795.1.1 Introduction 1795.1.2 History and ideas 1805.1.3 Types of BIM 1835.1.4 BIM around the world 1855.1.5 BIM and precast structures 1875.2 Technologies 1885.2.1 Industry foundation classes (IFC) 1885.2.2 IFC data file formats and data exchange technologies 1925.2.3 BIM model software 1955.3 BIM in precast construction 1985.3.1 Project pricing for precast structures based on 3D models 1985.3.2 Technical engineering 1985.3.3 Production data and status management 2025.3.4 Logistics, mounting, and quality management 2065.4 Summary 207References 2076 Mechanisation and Automation in Concrete Production 210Robert Neubauer6.1 Development of industrialization and automation in the concrete prefabrication industry 2106.1.1 Stationary flexible forms, tables and formwork in a prefabrication plant 2116.1.2 Long-bed production 2136.1.3 Pallet circulation plant 2176.1.4 CAD-CAM: the path to automation 2216.2 CAD-CAM BIM from Industry 2.0 to 4.0 2246.2.1 Production of non-variable parts versus production in lot size one 2246.2.2 IBS – suitable prefabricated products for mechanization and automation 2276.2.3 Just-in-time planning and production using ERP systems 2346.2.4 MES systems for mechanization and automation 2386.3 Automation methods 2426.3.1 From simple to the highly sophisticated 2436.3.2 Automation methods 2436.4 Integrated and automated prefabricated production process 2866.4.1 Structures 2876.4.2 ERP, CAD, MES, PROD machines, HMI 2896.4.3 HMI – integrating staff into the process 2896.4.4 Smart factory, industry 4.0 – integration into BIM 2916.4.5 QM included 2936.5 Limits of automation 2986.5.1 Labour cost versus automation 2986.5.2 Costs, necessary skills and ROI 2986.6 Summary and outlook 300Part 3 Industrialisation of Concrete Structures 3017 Lean Construction – Industrialisation of On-site Production Processes 303Gerhard Girmscheid7.1 Work process planning (WPP) 3047.1.1 Construction production planning process – introduction 3047.1.2 Construction production process – principles and sequence 3107.1.3 Systematic basic production process planning – steps 3117.1.4 Continuous construction process management 3137.2 Construction production process planning procedure 3147.3 Work process planning (WPP) – work execution estimation 3227.4 Work process planning (WPP) – planning the processes and construction methods 3297.5 Planning the execution process 3327.6 Procedure for selecting construction methods and processes 3367.6.1 Objectives when comparing construction methods 3367.6.2 Methodological approach to comparing construction methods 3387.7 Conclusions to Chapter 7 343References 3448 Lean Construction – Industrialisation of On-site Production Processes 346Gerhard Girmscheid8.1 Introduction – top-down / bottom-up work planning scheduling and resource planning 3478.2 Scheduling and resource planning 3488.3 Site Logistics 3528.3.1 Logistics planning 3528.3.2 Transport logistics 3548.3.3 Delivery, storage and turnaround logistics 3558.3.4 Planning storage areas – storage space management 3568.3.5 Disposal logistics 3578.4 Weekly work plans 3578.4.1 Lean construction – weekly work program 3578.4.2 Equipment and material call-up 3848.4.3 Organizing the construction workflow, construction methods, and health and safety 3908.5 Construction site controlling process 3918.5.1 Performance specifications 3918.5.2 Controlling weekly work performance 3938.6 CIP – the continuous improvement process 3988.7 Conclusions 401References 4039 New Cooperative Business Model – Industrialization of Off-Site Production 404Julia Selberherr9.1 Introduction 4059.2 Objectives of the new business model 4069.3 Modelling 4089.3.1 Formal structuring 4089.3.2 Contextual configuration of the outside view: development of the new service offer 4099.3.3 Contextual configuration of the inside view: Realization of the value creation process 4099.3.4 Overview 4209.4 Conclusion 420References 42110 Retrospective View and Future Initiatives in Industrialised Building System s (IBS) and Modernisation, Mechanisation and Industrialisation (MMI) 424Zuhairi Abd. Hamid, Foo Chee Hung, and Ahmad Hazim Abdul Rahim10.1 Industrialisation of the construction industry 42410.2 Overview on global housing prefabrication 42610.3 Housing prefabrication in Malaysia – the industrialisation building system (IBS) 42710.3.1 Chronology of IBS development in Malaysia 42910.3.2 IBS roadmap 43310.3.3 IBS adoption level in Malaysia 43510.4 Social acceptability of IBS in relation to housing 43910.5 IBS in future – opportunity for wider IBS adoption 44310.5.1 Greater Kuala Lumpur 44410.5.2 Affordable housing 44610.6 Conclusion 450References 45011 Affordable and Quality Housing Through Mechanization, Modernization and Mass Customisation 453Zuhairi Abd. Hamid, Foo CheeHung, and Gan Hock Beng11.1 Introduction 45311.2 Design for flexibility – insight from the vernacular architecture 45711.3 Scope of flexibility in residential housing 45911.4 Divergent Dwelling Design (D3) – proposed mass housing system for today and tomorrow 46111.5 Design principles of D3 46411.5.1 The design of the unit plan 46511.5.2 Unit configurations design 46611.5.3 Sustainable strategies design 46711.5.4 Structure and construction design 46811.6 Conclusion 472References 473Index 475