SMART REINFORCING

SMART REINFORCING
BETTER • FASTER • CHEAPER
MITA (P) 269/06/2003
July 2014
foreword
High impact, time saving prefabricated
solutions for vertical elements
In the bid to intensify land use and to maximize GFA, many public
agencies and private developers for industrial, commercial and
residential projects are going higher.
Over the last few years, 30 storey condominiums, 40 storey HDB
blocks and multi storey stack up factories have sprouted all over our
tiny little island where land cost is now among the highest in Asia.
In our endeavor to help our customers build faster and cheaper,
BRC has developed a complete suite of prefabricated solutions for
vertical elements – columns, walls, lift, staircase, shelter walls etc.
These solutions help to compress cycle time, reduce manpower and
improve site productivity so that our customers can build more with
less.
In this issue, we feature some of our high impact, time saving
prefabricated solutions for vertical elements. A cost comparison
between prefab and conventional steel fixing is also presented to
dispel the myth that prefab is more costly.
We welcome you to try our product and services to achieve a Better,
Faster, Cheaper and Higher outcome!
Lim Siak Meng
Group Managing Director
1
School Upgrading Project in Ang
Original reinforcement detail for lift wall.
1. Full set of lift wall panels delivered to site on a JIT basis.
Better
2. Door panel hoisted into position.
2
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7.8m high lift wall weighing 2.4 MT supplied in 5 panels.
Each panel took about 10 minutes to install.
The full set of wall panels took 2 hours to complete installation, including fixing of loose links by 4 workers.
Achieved productivity of 3.4 manhour/MT.
g Mo Kio - Prefab 2 Tier Lift Wall
8% Material Savings
Better
3. Prefab 2 tier lift wall completed for inspection and casting.
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Conventional steel fixing will take 4 workers 3 days to complete or 50 manhour/MT.
Productivity improvement of more than 95%.
Material savings of 8% from reduction of 1 lap.
Achieved same day inspection and casting.
3
8 Storey Industrial Park at Tuas
1. Cargo lift wall panels delivered to site.
Faster
2. 0.7 MT panel hoisted for installation.
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Cargo lift of size 2.7m (W) x 9.2m (L).
Floor height of 5.5m.
Reinforcement – T20-150 x T16-150.
Total weight – 16 MT.
3. Wall panels installed sequentially.
s South - Prefab Cargo Lift Wall
Original reinforcement detail for cargo lift wall.
80% Time Savings
Faster
4. Reinforcement for cargo lift wall completed with 17 prefab panels.
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6 workers took 6 hours to install 17 prefab wall panels or 2.3 manhour/MT.
Conventionally, it will take 6 workers 3 days to tie the reinforcement for the lift wall or 11.3 manhour/MT.
Achieved 80% time savings and cost savings from compressed construction cycle.
5
42Development
Storey Residential
Bu
Mixed
at Seng
Fonda
Original reinforcement detail for staircase shelter wall.
Cheaper
1. Full set of staircase reinforcement re-detailed in mesh /U-mesh.
6
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Staircase shelter wall of nominal size 6m (L) x 3.1m (W).
Reinforcement – T13-100 +T13-100.
Total weight – 3.5 MT.
23 sheets of mesh/U mesh took 5 workers 5 hours to install or 7.2 manhour/MT.
2. 23 sheets of me
uilding-at
RobinsonShelter
Road
Staircase
Wall
gkang
Fonda
Save 2 Days Per Floor
Cheaper
esh fully assembled to form the staircase shelter wall.
• Tying rebar manually will take 6 workers 2 days to complete or 35 manhour/MT.
• Productivity improved by 5 times.
• Savings of 2 days per floor.
7
42 Storey
Residential
Bu
5 Storey
Industrial
Developm
Fonda
Original detail for RC wall.
1. Prefab wall panel stored on site, ready for installatio
Better
3. 50 meter long prefab wall completed.
8
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50 meters of prefab wall measuring 5.2m high x 0.35m thick in 18 panels.
Reinforcement – T25-150 + T13-150.
Total weight – 16.5 MT.
Each panel took about 10 minutes to install and another 20 minutes to tie the horizontal lapping bars. 4 workers took 9 hours to complete the installation.
Productivity is 2.2 manhour/MT.
uildingatatPioneer
Robinson
Road
- Prefab
Wall
ment
Fonda
Reduce 2 Days Per Floor
on.
Better
2. First panel of 5.2 meter high wall installed.
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Conventional steel fixing will take 6 workers 3 days to complete or 11 manhour/MT.
Time savings of more than 80%.
Do not require scaffold during installation due to rigidity of the panels.
Reduced cycle time by at least 2 days.
9
42Industrial
Storey Residential
Bu
5 Storey
Developme
Fonda
Original reinforcement detail for lift wall.
Faster
1. Single cell lift wall reinforcement in a set consisting of prefab panels, mesh and links.
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10
Lift wall of size 3.8m (L) x 3.4m (W).
Reinforcement – T16 -125 +T13-200.
Total weight – 2.7 MT.
7 panels of prefab wall panels installed in 2 hours by 4 workers or 3 manhour/MT.
uilding
at Robinson
Road
- Prefab
Lift Wall
ent
at Pioneer
Fonda
85% Time Savings
Faster
2. Completed lift wall ready for inspection.
• Manual steel fixing will take 4 workers 1.5 days to complete or 22 manhour/MT.
• Achieved time savings of more than 85%.
11
42Public
Storey Housing
Residential
Bu
25 Storey
at Te
Fonda
Original reinforcement detail for flat beam along corridor.
Cheaper
1. 5.5m long prefab flat beam.
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12
Flat beam for corridor in public residential flat.
Typical size 5.5m (L) x 2.7m (W) x 0.2m (D) weighting 0.35 MT.
Prefab beam installed in 10 minutes by 2 workers or 1 manhour/MT.
Conventional fixing took 4 workers about 1 day for 5 flat beams on the same floor or 23 manhour/MT.
uilding
at Robinson
Road
- Prefab
Flat Beam
elok
Blangah
Fonda
NEW
!
Cheaper
Saves 1 Day Per Floor
2. Mechanical and electrical services in progress after the prefab flat beam is installed.
• Quick drop in installation allows time savings of at least 1 day per floor.
• Reduced cycle time by 1 day per floor.
13
25 Storey Public Housing at Telok Blangah
- Prefab Column
95% Time Savings
Better
A pair of prefab column rigidly standing in place.
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14
6.8m high prefab column for multi-storey carpark.
Weight range from 0.4 to 0.9 MT.
Each column took 2 workers 10 minutes to install.
Time savings of more than 95% compared to conventional steel fixing.
Cost Comparison / Benefits
- Prefab vs Conventional Steel Fixing
Chea
per O
Components
Prefab charge
In-situ steel fixing
In-situ prefab installation
Total
Conventional
Prefab
$/MT
$/MT
-
$ 150
$ 300
-
-
$120
$300
$270
ption
!
Fact
• Prefab cost is slightly cheaper but the main bulk of saving is from time saving and site productivity improvement.
Manpower Savings
• Productivity improvement of say 10 manhour/MT can result in a savings of 3000 man-day or 12 workers per year for a project with 3,000 MT of reinforcement. Assuming each worker cost the employer $2,500 per month (including levy and dormitory), the total savings amounts to $360,000 per year.
Better
Time Savings
• A reduction of 2 days per floor can shave 2 months off a 30 storey residential project.
Cost Savings
• Site overheads, equipment rental etc for a $50 million project is estimated to be $500,000 per month. Early completion of project by 2 months can yield a cost savings of $1 million!
15
Hotel at Alexander Road - Prefab Wall
Achieved 9 Days Floor Cycle
1. Panels of prefab wall standby for installation.
2. Wall reinforcement completed with 2 prefab panels and 2 sheets of mesh.
• Wall measuring 6.7m (L) x 4.3m (H).
• Total weight – 1.2 MT.
• Full set of wall took 3 workers 30 minutes to complete or 1.25 manhour/MT.
• Conventionally, it will take 3 workers 6 hours to complete tying loose bars or 14 manhour/MT.
• Time savings of more than 90% and achieved cycle time of 9 days.
• Inspection and casting done on the same day.
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