2

3

4

• Zone Innovation Park is one of the largest industrial parks strategically located in Sungai Kapar Indah, North Klang.

• Developed by Titijaya Land Berhad, this project consists of 100 units 1½ & 2½ Semi-Detached factories and two units Bungalow factories.

• The Semi-Detached factories have a built-up area of 6,825 square feet.

• The project covers about 43 acres of freehold land.

• Construction took place in August 2014 and is scheduled to complete in early 2016.

Key Plan Location Plan

Artist’s Impression

5

6

Construction Signboard • Signboard functions as a form of communication with the public. • The information listed on the board includes the project work to be

carried out and the contacts of different bodies involved mainly the project owner, architect, structural engineer, M&E engineer, landscape architect, developer, quantity surveyor, and contractor.

• The start and finish dates of the project are included as well. • This construction board is erected at the entrance of the site throughout

the entire construction process and is visible to the public.

Safety Signboards • Under the Factories and Machinery (Building Operations And Works Of Engineering Construction)

Regulations 1986 covered by the Department of Occupational Safety and Health (DOSH): 48. Danger Sign A simple but effective warning notice in the national language shall be place in a conspicuous position at the discharge end of every chute to warn the employees and public.

• Safety signboards are placed at the entrance of the construction site to warn people on or near this site of all hazardous activities taking place.

7

Front Elevation Side Elevation

8

Hoardings • Under the guidelines covered by the Department of Occupational Safety and Health (DOSH):

11.1 The worksite should be fully barricaded by protective hoarding so that the general public would be protected from work in progress. The hoarding should be able to protect not only public from dangers within the site but also act as barrier or security to prevent persons from trespassing into the site.

• Each hoarding panel in this construction site is 10ft x 8ft made from steel and painted with two coats of zinc chromate and one finishing coat.

• They provide protection for the public, resist impact damage and anticipated wind pressures.

• Before a hoarding can be erected, a license must be obtained from the local authority.

Elevation of Hoarding Section A-A

Scaffolds • Under the guidelines covered by the Department of Occupational Safety and

Health (DOSH): 20.1.7 All scaffolds require bracing to help prevent them from collapsing. All scaffolds, including ‘independent scaffolds, should be secured tied, or otherwise supported.

• Scaffolds are temporary frame constructed from steel coupled together to provide access to high-level working areas and safe working platforms (scaffold boards).

• They are required when the working height is 1.5m or more above the ground level.

9

Concrete Work • Under the guidelines covered by the Department of Occupational Safety and

Health (DOSH): 20.4.1 Formwork and reshores shall be certified structurally safe by a Professional Engineer and shall be properly braced or tied together so as to maintain position and shape.

• Shoring frames are used to provide vertical support to horizontal formwork for slabs and beams.

10

First Aid Kit

• Under the Factories and Machinery (Safety, Health And Welfare) Regulations 1970 covered by the Department of Occupational Safety and Health (DOSH): 38. First Aid Any injured person shall at all times receive prompt first-aid treatment and such further medical attention as may be necessary.

• The first-aid box is marked with a crescent on a white background. Only one first aid kit is available on the site and is placed in the construction site office.

Safety Helmets • Under the Factories and Machinery (Safety, Health And Welfare) Regulations

1970 covered by the Department of Occupational Safety and Health (DOSH): 32. Safety Helmets (b) Every person exposed to falling or flying objects and blows on the head shall wear well fitting industrial safety helmets.

• Safety helmets help to absorb the force generated when a falling item strikes the helmet.

Excavating and Earth Moving Equipment

11

Excavators • They are used primarily to excavate and load

most types of soil. • These machines are suitable for trench and

foundation excavations. • The power unit is a tracked based machine

with a slewing capacity of 360 degrees.

Backhoe-loaders • They are a four-wheel drive machines and are

intended mainly for use in conjunction with small excavation works.

• These excavators are fitted with a loading/excavating front bucket and a rear backacter bucket both being hydraulically controlled.

• Most machines can be fitted with a variety of bucket widths and various attachments.

Highway Dumpers • Dumpers are used for horizontal transportation of materials on and off the construction site by means of an integral

tipping skip. • These dumpers can be used to carry materials such as excavated spoil. • These machines are designed to traverse rough terrain but they are not designed to carry passengers.

Trucks and Hauling Equipment

12

13

Telescoping-Boom Truck Mounted Mobile Crane • The cranes are lifting devices designed to raise materials by means

of rope operation. • These mobile cranes consist of a telescopic boom mounted on a

specially adopted truck. • They have two operating positions: the truck being driven from a

conventional front cab and the crane being controlled from a different location.

• Truck mounted telescopic cranes require a firm surface from which to operate.

Lifting and Vertical Transportation Equipment

Concrete Mixer • They are used to mix and transport small

batch concrete and mortar mixes. • The single-compartment drum has an

inclinable axis with loading and discharge through the front opening.

• These tilting mixers have fixed blades inside the revolving drum that lift the mixture and at a certain point in each revolution allow the mixture to drop towards the bottom of the drum to recommence the mixing cycle.

Concreting Plant

14

Concrete Mixer Trucks • They are used to transport mixed concrete

from a mixing plant to the site. • Discharge can be direct into placing position

via a chute or into some form of site transport such as a dumper.

• This method of concrete supply can eliminate the need for site space to accommodate storage of materials, mixing plant and the need to employ workers who can constantly produce consistent concrete mixes.

Piling-Driving Equipment

15

Piling Rigs • Piling rigs or pile drivers are mechanical

machines used to drive piles into the ground to transfer both vertical and lateral superstructure loads through the soil strata.

• These pile drivers have leaders to hold and guide the hammers and piles as they are driven into the soil.

• The ram is lifted to a pre-set height and allowed to free-fall onto the helmet.

Vibratory Pile Drivers • These drivers are especially effective when the piles are

driven into water-saturated non-cohesive soils. • The drivers are equipped with horizontal shafts, to which

eccentric weights are attached. • As the shafts rotate in pairs, in opposing directions, the

forces produced by the rotating weights produce vibrations. The vibrations are transmitted to the pile because it is rigidly connected to the driver by clamps.

16

• When construction vehicles are leaving the site, their tires are cleaned by water sprayed with water hoses. • However, the usage of water hoses in this construction site to clean the vehicles is proven ineffective as the volume flow is

extremely low to clean and remove the wash sludge.

• One of the alternatives to water sprays is the installation of a drive-through washing system. • Drive-through systems allow trucks and other machineries to pass through without stopping while getting the tires, wheel wells

and mud flaps cleaned. • This procedure helps to control and eliminate the pollution of public roads. • The high volume flow of water flow cleans the tires and effectively remove the wash sludge slurry from the wash platform into

the recycling and solids collection tanks.

Wheel Washing System

The ineffective method of using water hoses A proposed drive-through system MobyDick Quick

17

Site Clearing

18

• Site clearing is a process where vegetation, debris, or other obstruction in the site is cleared. Site clearing includes removal of vegetation which consists of the removal of trees and stumps that are within the boundary of the construction site.

• This process happens after fencing and provides a obstruction free land to start construction on. • The method chosen for the conducting the site clearance work will be determined by the scale od the development, and

by consideration for any adjacent buildings.

Setting Out

19

• Setting out is the establishment of the marks and lines to define the position and level of the elements for the construction work so that works may proceed with the reference to them.

• A building is set out in order to clearly define the outline of the excavation and the center line of the walls, so that construction can be carried out exactly according to the plan. The center line method of setting out is generally preferred and adopted.

• A control grid enables points to be set over a large area. Several different grids can be used in setting out.

• Whether used in the form of a baseline or a grid, the horizontal control points are used to establish design points on the proposed structure.

• Once excavations for the foundations begin, the corner pegs will be lost. To avoid this extra pegs called offset pegs are used.

Setting Out

20

• After the baseline has been set out, a check should be made of the setting out lines for the right angles and correct length. • The diagrams below is illustrate the methods of checking the right angles.

Trench width

Wall width

150 X 38 boards

Position of trench plumbed down

Setting-out lines

Nails positioning trench and walls

50X50 pointed posts driven into ground

Setting out line Setting out line

2000

50 X 50 corner post

2000

Square out of 150 X 38 softwood

Datum Post Main setting out lines Profile boards

Diagonal Check

Site Boundary

Baseline

Typical profile board

Setting out and checking methods

• After the setting out of the main building lines has been completed and checked, profile boards are set up as shown in the diagram of typical profile board.

• These are the set up clear of the foundation trench positions to locate the trench, foundation and walls.

Earthwork

21

• Earthwork carried out to remove earth to from a flat site or form a cavity of the site before the grading of the soil. • Earthwork including the process of excavating, hauling, dumping, crushing and compacting. • Excavation can be classified in two ways. Firstly by the type of material that is being excavated and secondly by the

purpose of the excavation. • When classification is based upon material type, it is very important that the material is accurately identified to keep costs

down and prevent technical problems occurring. • Four general categories are: 1. Easy – loose free flowing soil or sand 2. Medium – gravel with clay 3. Medium to Hard – wet heavy clay, broken rock, gravel with boulders 4. Hard – materials requiring blasting

This is the structure of loose soil or sand

This is the structure of compact soil / clay

Earthwork

22

• There are a few types of earthwork carried out. Firstly, the drainage excavation. Drainage excavation is the removal of the materials encounter during the installation of drainage structures such as pipes and culverts. After installation, backfilling is done with an acceptable material.

• Second is excavation over site. It is the removal of topsoil 150mm-300mm in depth.

• Next is cut and fill, it is to level hilly or uneven landscape to produce flat land.

represent original level.

Represent cut line

Earthwork

23

• Sides of trenches and pits are important to be stable to keep the workers and concrete safe and these depend on: 1. Type of soil 2. Water ground and its movement 3. Deep of excavation 4. Loads • Trench and pit excavation provide a place for locating the footing. Depth varies but has to be able to provide sufficient

support for footings.

• Above images is the general procedure for the excavation of trenches.

Sight rail

Boning rod

Sight line

Ground level

Depth foundation

Sight rail replaced at a known height (could be profile board)

Support post

Straight rail

Boning Rod Alternative: support post placed in pipe filled with sand or earth

Hoarding

24

• Appropriate fencing or hoarding is needed for safety purpose. It is used to secure the construction site and it define the site boundary.

• The authorized party enter through the access gate.

• It is to keep away the unauthorized party and also people that suddenly wandering around to reduce the risk of injuries.

Site Office and Security

• The site security is constructed at the entrance of the site. It is to keeping record od people that entering or exiting the site.

• The Site Office found on the construction site. It is a temporary structure that actually a portable cabin. It’s is durable and functional.

• It constructed in a very simple construction method.

Construction Site Storage

25

• The type construction storage facilities is depend on the durability of the materials.

• The materials have to kept properly to avoid damage and cause wastage.

• Wastage is unwanted as it will rises the cost of the construction project.

• Some materials store openly as it can withstand the weather and would not require any protection. Sometimes, temporary storage areas are used to store materials that require protection from weather for a short time of period.

• The more expensive materials are kept in the storage cabin to avoid damage or steal.

Canteen

• Canteen can be found in the construction site. It provides foods and beverages to the workers from the site.

• Some of the workers build up their own cooking area to prepare their own meals.

Temporary Toilet

26

• Toilet can be found beside the site office and workers’ quarters.

• To provide relief facilities for the workers.

Temporary Water and Electrical Supplies

• The electrical supply is often used the electrical generator to provide electricity.

• The water storage is also found around the construction site to provide sufficient water for the workers.

• According to the site manager, installation of water supply and electrical supply is normally on a week or 2 weeks before the construction started.

Drainage

27

• Drainage is the system of underground pipes used to convey discharge from the roofs, paved areas and sanitary fittings to a suitable disposal installation.

• There are many types of waste pipes in different dimension and sizes. Before installation of water pipers, the degree of slop is an important aspect to be considered.

• Water pipes can range in size from giant mains of up to 3.65 m in diameter to small 12.7 mm pipes used to feed individual outlets within a building.

• Materials commonly used to construct water pipes include polyvinyl chloride (PVC), cast iron, copper, steel and in older systems concrete or fired clay.

• Drainage normally built during the final stage of the construction before the construction of road. This is to allow the access of machinery.

Sewerage

28

• Sewerage is the removal of waste water and refuse by means of sewers. • According to the site manager, there are two type of bricks used for the sewerage system. One is the clay/red brick and

one is the sand brick. • The red brick is used to discharge chemical wastage. The red brick will not corrode when contact with the chemical. The

sand brick is to discharge water waste.

• From the site, the size of the pipes are indicated by using the two different colours.

Hygiene

29

• Regarding to the site we went, there is no proper way to manage the rubbish. • The rubbish littered around the site and it produce a very stingy smell. • The water accumulated at the site will also cause dengue mosquitos produce their offspring.

30

Foundation

31

• Foundation design is a specialized field that must account for the interaction of building loads with the various soil, rock, and water conditions encountered below the surface of the ground.

• The choice of foundation type can have a significant impact on building costs, construction schedule, and choice of structural systems for the remainder of the building.

• There are two types of foundation that employed within our site:

Superstructure

Substructure

Roof loads transferred onto walls

Floor loads transferred onto walls

Foundation spread load to ground

Shallow Foundation (Pad Foundation) • Footings are employed

when stable soil of adequate bearing capacity occurs relatively near to the ground surface.

Deep Foundation (Pile Foundation) Pile foundation employed when the soil underlying a foundation is unstable or of inadequate bearing capacity. They extended down through unsuitable soil to transfer building loads to a more appropriate bearing stratum of rock or dense sand.

Piles

32

• A pile foundation is widely used in the construction industry and it is categorized as a deep foundation.

• The dimensions of the R.C square pile used in our site is 200mmx200mm. The piles are 12m long. The minimum concrete grade for piles is 45N/mm2 (G45).

Piled foundation in our site is classified as End Bearing Pile.

Piles are columnar elements in a foundation that able to spread the load of the superstructure over a large base to reduce the load per unit area.

The type of piles that have been used in our site is Precast Reinforced Concrete (R.C) Square Piles.

The advantages of the driven R.C piles: • Construction operations not affected by ground water • Can be driven in very long lengths • Can be designed to withstand high bending and tensile stress

Piling Process

33

STEP #1 • Transportation of piles to designated area that has been excavated using a

crane. • The piles are all transported carefully as they are easily breakable.

STEP #2 • As the pile is tied up to its lifting lug. • The pile is ready for hammering.

34

STEP #3 • Before hammering process begins, they are all positioned accordingly to

be driven into the ground.

STEP #4 • Hammering process begins. • The pile is driven into the ground using a drop hammer. • The subsoil around the pile shaft is displaced. • The pile is driven to its maximum depth until it cannot

be driven.

Piling Process

Pile Cap

35

• Pile cap has the function of spreading the load from a compression or tension member onto a group of piles so that the load is shared equally between the piles. The pile cap also accommodates deviations from the intended positions of piles, and by rigidly connecting all the piles in one group by a massive block of concrete.

Single pile

Two-pile group

Three-pile group

Pile Cap

36

• Types of pile caps that has been used in our site.

Section of pile cap with rebar The minimum concrete grade for piles is 30N/mm2 (G30).

Pad Foundations (Footings)

37

• A common method of providing the foundation for columns of framed structures. It can be mass concrete, but usually reinforced to limit the amount of excavation and concrete fill.

Pad foundations are usually square on plan

Isometric view with rebar

The area of pad required is obtained by dividing the load on the subsoil by the safe bearing capacity of the subsoil.

Casting of pad footings. Pad footing in our site are used to support individual columns.

R.C. Stump Ground beam

Pad footing Stump reinforcement

Plan, section and isometric view of pad footing

38

• Begins with a formwork. • Form work is built using

wood framing template.

• Reinforcement rebars are placed in erected formwork.

• At the centre of the footing, stump reinforcement is erected.

• Anti – termite treatment is applied to prevent infestation.

STEP #1 STEP #2 STEP #3

Footing Process

39

Footing Process

• After treatment, more ties are added and concrete is poured into the formwork.

• Footing formwork is detached after concrete has been successfully cured, and hardened to the appropriate strength.

STEP #4 STEP #5

40

41

Beams

• The doubly reinforced beams used on our site are entirely reinforced concrete (RC). • Reinforced concrete is a combination of traditional cement concrete with reinforcements (steel bars) known as rebar. This

combination is made to utilize the compressive strength of concrete and tensile strength of steel simultaneously. This strengthens concrete beams, columns, and slabs by providing more resistance towards compression and tension forces.

Beam Ground Beam

• Reinforced concrete beams are a horizontal structural component designed to carry load. Due to the large span of the project, a continuous beam is used as the weight is distributed throughout its length of the factory which is 36.894 meters.

Continuous Beam

Rebar Cage used in reinforced concrete

Section of a doubly reinforced beam

• Without reinforcement, beams will crack when too much pressure is applied to it.

• The bottom bar withstands more tensile fore as force is being applied downwards.

Rebar cage

42

Process of In-situ Casted Beams 1. Rebars are joint with column’s extended rebars. Timber framework is constructed around it and scaffolding is set up to

help support the formwork and concrete. 2. After the formwork has been constructed, concrete is poured into the timber formwork. 3. After 14 days of setting, the formwork is removed to reveal the reinforced concrete beam.

• Stirrups are placed perpendicular to the longitudinal bar to resist the vertical component of a diagonal force.

• Beam width should be equal or greater than width of supporting column.

• Depth of beam is span divided by 16.

• Longitudinal bar serves as tension reinforcement.

43

Link

1. Ground is excavated to allow the rebar and beam to go in place. Timber frame work is constructed around the rebars in the excavated land.

2. After the formwork is being constructed, concrete is poured into the timber formwork. 3. After 14 days of setting, the formwork is removed to reveal he reinforced concrete beam.

Process of In-situ Casted Ground Beams

Main Vertical Reinforcing Bars

Carrier Wires for Holdings Purpose only

Column Links

• Column links are wrapped around the steel bars and serves as secondary reinforcement to concrete beams or columns after rebar as it adds a secondary layer of stability to the structure.

• Links are shaped rectangular to cover the four corners of the rebar and concrete during construction phase.

44

Bar Curtailments for Beams longer than 12 meters on site

Bar Curtailments for Beams on site

45

• Reinforced concrete slabs are plate structures laid with reinforcement bars to withstand load. • It is supported by beams. Hence, force applied to slabs are transferred to beams. • All Slabs on site are of 125mm thickness.

Slabs

Beams supporting slab

Reinforcement bar for slabs

46

Ground Slabs

Polyethylene moisture barrier

One Way Slab

• Our site mainly uses one way slabs, where slabs are reinforced in one direction and they are casted on a series of parallel beams or walls.

• Force is transferred in parallel of beams.

• Suitable for light load and span of slab is relatively short.

Parallel Beams

Parallel arranged beams

Concrete Slab • Thickness depends on the load it has to

bear. • Minimum thickness is 100mm. • Additives may be added to increase.

surface hardness and abrasion resistance. Damp Proof Membrane • Polyethylene moisture barrier to prevent

water from entering the structure. • Thickness of polyethylene is 0.15mm.

Gravel Stone • Gravel Stone is laid as a base to prevent

the capillary rise of groundwater. • Minimum thickness is 100mm.

47

• Reinforcement bar placed perpendicularly.

• Size of reinforcement bar used differs according to the load it has to bear.

• Thickness of floor slab depends on the load it has to bear.

• Minimum thickness of slab is 100mm.

• Beam that supports the slab.

Top Reinforcement for Slabs detailing

Internal Non-Suspended Slab For Ground Floor detailing

Apron Slab detailing

Bar Curtailments for Suspended Slabs on site. ( Non Fabric Reinforcement)

48

• Before the concrete is poured into the formwork, spacer blocks are placed in between the rebar and the ground to prevent corrosion. These blocks are just pieces of cut concrete in cube or cuboid shapes.

• The spacer blocks help elevate the rebar from touching the ground. The weight of the concrete, without the spacer blocks, push the weight on the rebar, contorting it to the point where the rebar touches the ground which puts the rebar at risk of corrosion.

1. Underside of slab are provided with 25mm lean concrete. 2. Rebar is set, and formwork is constructed to hold the concrete. 3. Scaffolding is inserted to support the formwork. 4. Concrete is poured in and after 14 days of setting, scaffolding and

formwork is removed to reveal the slab.

Process of In-situ Casted Slabs Spacer Block

Spacer Block

49

1. The columns used in our site are all reinforced concrete (RC). 2. The columns come in different thicknesses, this is due to the different forces acting on the

column. The larger the force acting on it, the thicker it has to be to be able to withstand that force.

Columns

1. After the rebar is set, timber formwork is constructed around it to act as a cast. 2. After the formwork has been constructed, concrete is poured down the formwork. 3. After 14 days, the formwork is removed to reveal the column.

Process of In-situ Casted Columns

50

• Length of overlapping reinforcement bar is forty times of the diameter of the bar.

• Dowels tie column to supported beam or slab.

• Vertical reinforcement should not be less than 1% nor more than 8% of the cross sectional concrete beam.

• Types of reinforcement steel includes T12, T14, T16, T20, T25, T32, and T40.

• ‘T’ represents reinforcement steel and numbers indicates the diameter.

Lateral Reinforcement •

• Number of reinforcement bar used in columns may be

varied instead of varying the size of column. • Lateral ties should have a minimum diameter of 10mm. • Space between two ties is not more than 48 tie

diameter. • Type of reinforcement used is usually T12,

reinforcement steel with a diameter of 12mm. • Concrete columns may be supported by

isolated footings or by pile caps.

On site Column reinforcement splicing details

Detail ‘A’

51

A

B

• As seen in the ground floor plans. It is obvious that columns A and B are of different thicknesses. Column B is thicker than column A.

• This is because column B is carrying more load. As seen in the second floor plan, the second floor exert force onto columns under it.

• Hence, columns supporting the second floor has to be thicker than columns that are only supporting the roof. So that the column is strong enough to withstand the force exerted onto it by the second floor.

• As seen in the b=picture to the left, there are also difference in thickness of columns between the lower half and upper half.

• The same reasons being the lower column is carrying a heavier load. Hence, it is thicker.

Ground Floor Plan Second Floor Plan

52

Step By Step Construction Process (Beams, Slabs, And Columns)

Setting up of reinforcement bars and number of bars used depends on the load it has to bear.

Cladding of formwork using plywood.

Cement is being pumped and poured into the formwork. A concrete vibrator is then used to release trapped air and excess water.

When the concrete of the columns have dried up, cladding of formwork for beams can be done.

Reinforcement bars for beams are set up.

Cement is pouted into the formwork. A concrete vibrator is then used to ensure that the concrete settles firmly in place.

Columns and beams are formed.

1.

5.

4.

3.

2.

7.

6.

53

Ledger is set for the beams.

Bearers are then installed in intervals of 300mm.

Plywood are installed side by side and bases are installed between the bearers.

The props is set for slab installation. The ledgers for slab will be set in an interval of 200mm. Then, plywood decking will be laid on the props setting.

Plywood Deck

Reinforcement Cages

8. 10.

9. 11.

54

Cement is poured to form the concrete slab. The cement is transported by a concrete pump.

Dismantlement of the wooden formwork will occur after the concrete is set and have gained enough strength.

14.

15.

Electrical wiring system is installed before placing the bottom reinforcement.

13.

12.

Spacer blocks are placed on the plywood decking which allows sufficient concrete cover.

Spacer Block

55

Walls

• From the image shown to the left that was taken at site, we can see this wall is a non load bearing wall, where the load is supported by beams and columns. All bricks for the factories are lightweight blocks known as autoclaved aerated concrete (AAC).

• The styles and methods in which the bricks are laid to form the wall. For our site, Running forms of brick layering are most commonly used, with both proving to be a great choice in dealing with not only leads, but also the climate and conditions on a hot and humid country such as Malaysia.

56

Autoclaved Aerated Concrete (AAC) Block

• AAC products are a sustainable material and contains up to 20% of recycled materials. It provides long life span and is also recyclable, making it an exceptionally green building material.

• Comes in two sizes 600 x 200, 625 x 200 (height x length in mm). • With thicknesses 50, 75, 100, 125, 150, 175, 200, 225, 250, 300mm. • The AAC blocks on site primarily uses blocks with thickness 150mm. • One AAC block is equivalent to 7 normal bricks in terms of size. • Whereas the weight of one AAC brick is 12kg, and a normal brick is weighted between

2-3kg. One AAC block weighting 12kg would replace 7 normal bricks weighting between 14-21kg. Hence the use of AAC is brick does indeed lighten the load and the entire factory building.

• Having a lighter building would result in lesser foundation required to support the building. Hence lowering construction cost.

• Besides that, AAC bricks provides heat insulation 6 times superior than normal clay bricks. Where in our site, no special coating on walls has been added for insulation purposes. Hence, the usage of AAC bricks is sufficient to provide enough heat insulation.

Wall Types Normal walls • 115mm thick.

Party walls • Wall between two factories • Acts as fire wall. Slows down spread of fire. • 230mm thick.

NOTE: For our site, the wall between factory and office area is also 230mm thick, same as party walls.

57

L Shaped corner Bead

• Used to protect the edges.

• Often done before plastering

• Provides a smooth corner to the wall

• after plastering

Wall Stiffener

• As seen in the photo on the left, wall stiffeners are thinner than beams and are mainly used to provide rigidity to the structure, and to prevent it from collapsing.

• Wall stiffeners are used in our site mainly because of the high height of the factory.

Parapets • Extended exterior wall to prevent spread of fire from roof

to roof. • Parapets on our site are 1.2 meters high.

Coping Beam for 115mm parapet brick wall details

58

1. Calculations are made, then layering styles are chosen that best fit the criteria. (Normal wall: 115mm) (Party wall: 230mm) 2. Layering process begins, blocks are joined together using thin bed adhesive. 3. Lines are hooked up at ends of walls as a indicator to ensure that every brick is in line. 4. Bricks that are too long are sawed to correct lengths in order to fit. 5. As the wall starts to reach the stiffeners or beams, the little space left is stuffed with broken up pieces of bricks along with

mortar. 6. All walls are then coated with 19mm thick cement plaster on both sides.

Process of Layering Wall

59

Stairs

U Shape Staircase with landing

• A U-shape staircase has a landing that changes direction 180 degrees and also serves as a pace for rest when moving. The landing divides the staircase into two, thereby reducing quantity of treads in one flight, making the walk up more comfortable.

• This kind of stairs are more compact and hence used in our site, to ensure there is sufficient space in the office area.

• In our site, stairs are mostly made of reinforced concrete. A concrete staircase is designed as an inclined slab with steps formed on its upper surface. Thus, it often requires careful analysis of load, span and support conditions.

• Handrails in our site are made of mild steel. Where its connection with the concrete staircase is a metal lug inserted into the concrete. Details are shown in the following pages. There are also a few threads on the staircase for slip resistance.

60

Process of In-situ Casted Staircase 1. First, temporary panes are set up to

lay out the treads and risers. Then the slab thickness is measured at the right angle to the slope of the stairway.

2. Next, the soffit panel thickness, joist width, stringer width and snap lines are laid out. Shore length and the side form width are then determined afterwards.

3. Next step, the shores are cut to length and secured in position. Stringers are nailed to the tops of the shores, joists are nailed to the tops of the stringers and soffit panels are nailed in position. Then, the temporary panels are removed.

4. Treads and risers are laid out on the side forms while plates from both ends and stiffeners are nailed. The side forms are then fastened to the top of the joists. After rebar is placed, cleats and riser form boards are fastened to the side forms. Finally, the front section is nailed into place.

On-site Typical Section of Staircase

61

On-site Typical Staircase Measurement Details

On-site Typical Railing Details

62

63

Types of doors used in site: • Aluminium frame double-leaved tinted glass door • Timber door with GJ sheet • 1 HR fire rated door • Motorised roller shutter door prepainted zincalum steel

Door Types

64

Advantages: • Lightweight and durable compared to steel. • Corrosion and rust resistant, requiring minimal maintenance. • Easy to install. • Significantly less expensive than other options, providing the

most economical option.

Aluminium Framed Doors

65

Process

1. A hole is left in the brickwork in an approximate size of the door frame.

2. Concrete is shaped to fill the voids into the rough size of the door frame.

66

Process

3. The door and frame is inserted into the concrete hole and secured with concrete nails.

4. The metal strip around the edges is covered with cement plaster.

67

Advantages: • Vertical mechanism allows for more space in the interior. • Provides good insulation from weather, i.e. wind, rain, haze. • Protects the building from vandalism and burglary attempts.

Roller Shutter Doors

68

1. Vertical support angles are fixed onto the edges and screwed in.

2. The rotating barrel is fixed onto the top of the support angles.

3. The key unit is connected to the power supply and fixed onto the wall.

4. Top section of curtain is secured to the barrel and the curtain is adjusted.

5. Guide rails are placed into position and secured to the vertical support angles.

Process

69

Aluminium Frame Glass Windows

Advantages: • Aluminium has a high strength-to-weight ratio, meaning it is durable yet lightweight. • Aluminium is corrosion-resistant, reducing the need of maintenance • Economically efficient material that is strong for its cost. • Flexible and able to meet many architectural specifications. • Meets the highest standard for air and water infiltration and structural integrity.

70

Process

1. A hole is left in the brickwork in an approximate size of the window frame

2. Concrete is poured and molded to the approximate size of the window.

71

Process

3. The window is inserted into the concrete hole, with the metal strip gripping the concrete edges and secured with concrete nails.

4. The metal strip around the edges is covered with cement plaster.

72

73

Flat roofing consists of a horizontal base which is fixed to the ceiling joists underneath with a waterproof membrane applied on top. Advantages: • Offers significantly more stability and horizontal

surface than sloped roofs do. • More affordable option at the point of construction,

involves considerably less materials and labor than a pitched roof.

Disadvantages: • Drainage, or lack thereof, water hence has a

tendency to puddle and remain on the roof. • Leads to the roofing material breaking down or to

eventual leaks, particularly along the seams.

Flat Roof (Office)

74

Structure of Flat Roof

Type of metal roof deck:

Klip-Lok Classic 700 dimension, 5˚ pitch roof

47 mm

250 mm

75 mm

20 mm

C-channel Steel Purlin dimension

Type of purlin:

Flat roof has a structure of:

Metal roof decking

Reinforced concrete walls (beams)

C-channel purlins

RC concrete beam, purlins and decking

75

Metal Roof Decking

Guo Foil Sisalation Sheet (Aluminum Foil) • Keeps the internal accommodation cool by reflecting sun

oriented high temperature that transmits from the sun.

50mm Thick Rockwool Insulation • Highly efficient at blocking heat transfer, protects against

unwanted noise, fire and reduces energy consumption.

Steel Rafter • To support the roof system, it is strong, rigid, durable, light;

it has high workability and corrosion protection.

Chicken Wire Mesh • Lays down on steel rafter, has high tensile strength and

corrosion resistance.

C-channel Purlin • High tensile steel, anti corrosion and long-lasting; supports

the loads from the roof deck firmly.

76

Purlin Bridging: Anti-Sag Rods/Tie

Anti-sag rods are designed to restrain purlins against twist under wind uplift conditions and contribute support during sheeting.

Anti-sag tie dimension

Multilok Tie Arrangement

77

The procedure to bridge anti-sag rods to C-channel purlins is to commence from the eave or ridge: Step 1: • Install the fascia bridging assembly by inserting the locator end into the

holes of the first purlin, and bolting the fascia bracket to the fascia purlin.

Step 2: • Install the standard bridging assemblies working towards, and finishing

at the ridge purlin. Standard assemblies are installed by fitting the clamp end over the previously-installed locator end and swinging the bridging around until the locator end engages in the holes of the next purlin.

Step 3: • Install the ridge bridging assembly by fitting the clamp ends over the

previously installed locator ends and then tightening the bolts of the ridge assembly. When a ridge bridging assembly is not used, the locator(s) of the standard bridging is secured into position with two bolts.

Step 4: • Where turnbuckles are used in a bridging assembly, first align the

purlins. align the fascia purlin using the, adjustment bolts of the fascia bridging assembly.

78

Connection between Purlin and RC Roof Beam Details

79

Pitched Roof (Office)

Pitched roof is a roof sloping downward in two parts at an angle from a central ridge, so as to leave a gable at each end. Advantages: • A slight pitch of only a few degrees is incorporated

to enable rainwater to drain away into a hopper. • The internal accommodation will be more efficiently

insulated and will not suffer from the extremes of temperature.

Disadvantages: • The more complex design, additional building

materials and extra man-hours cost significantly more than a flat roof.

• Places a greater burden on the foundations of the building.

80

Structure of Pitched Roof

Pitched roof has a structure of:

Reinforced concrete beams

C-channel purlins

Metal roof decking

2. Steel truss system

1. RC concrete beam, purlins and decking

Pratt trusses have vertical web members in compression and diagonal web members in tension. It is generally more efficient to use a truss type in which the longer web members are loaded in tension.

3. Fascia truss system

Fascia is a vertical frieze or band under a roof edge. It is used as a base to attach the gutters to, and as a cover to hide the fixing space between the roof, eaves and wall.

81

Steel Truss System

Reinforced concrete column support.

Metal roof decking span purlin spaces.

C-channel purlins span the truss spacing.

Steel bearing plate. Trusses require lateral bracing in a direction perpendicular to their planes.

Mechanical services such as piping, conduit and ductwork may pass through the web spaces.

Steel trusses are fabricated by welding or bolting structural angles and tees together with gusset plate connectors to form the triangulated framework.

82

Truss Connection Details

Connection from truss to column

Connection from truss to steel column detail

Fly bracing section

Connection from truss to RC column detail

83

Fascia Truss Connection Details

Fascia Truss Detail

Side Fascia Truss Detail

84

Roof Flashing

Transverse flashings

Flat to pitched roof flashing

• Flashing is the thin continuous pieces of sheet metal to prevent the passage of water into a structure from an angle or joint.

• At our site, the flashing is concealed. The method of flashing used is transverse flashings. Transverse flashings have a stiffening lip, along the lower edge, which is turned-down to dip into the pan or valley. To maximize weatherproofing, the bent lip is profited to fit.

Our site building: • Front: Office (Flat roof) • Rear: Warehouse (Pitched roof) Thus, the water flows from flat to pitched roof.

85

86

Throughout this project, we were able to experience the basic principles and procedures of a construction process of factories in North Klang through our own observations. We were exposed to construction technology, the processes being carried out for different building elements, terminologies, application of materials, site hazards and safety, and the machineries used. We further analyzed these construction elements by applying our knowledge and eventually produced a complete documentation.

We would like to extend our appreciation to Titijaya Land Berhad for allowing us to record and document the entire construction process and also the project site manager, Mr Ng Shim Yen, for explaining and guiding us along the way to finishing our report.

87

88

Introduction to Site • Zone Innovation Park @ Klang. (n.d.). Retrieved September 29, 2015, from http://www.titijaya.com.my/current-projects/zone-innovation-

park-klang

Site and Safety • Chudley, R., & Greeno, R. (2014). Building Construction Handbook. New York, NY: Routledge. • Chudley, R., & Greeno, R. (2006). Advanced Construction Technology (4th ed.). United Kingdom: Pearson Education Limited. • Peurifoy, Robert L., Schexnayder, Clifford J., & Shapira, A. (2006). Construction Planning, Equipment, And Methods, Seventh Edition. New York,

NY: McGraw-Hill. • Sarkar, Subir K., & Saraswati, S. (2012). Construction Technology. New Delhi, India: Oxford University Press. • Heberle, D. (1998). Construction Safety Manual. New York, NY: McGraw-Hill. • Department of Occupational Safety and Health. (n.d.). Retrieved October 2, 2015, from http://www.dosh.gov.my/ • Site signage. (n.d.). Retrieved October 15, 2015, from https://www.masterbuilders.asn.au/health-safety-and-environment/site-signage • Wheel washing system. (n.d.). Retrieved October 20, 2015, from https://en.wikipedia.org/wiki/Wheel_washing_system

External Work • Chudley, R., & Greeno, R. (1999). Construction Technology (3rd ed.). Harlow: Longman. • Chudley, R., & Greeno, R. (2010). Building Construction Handbook (8th ed.). Amsterdam: Butterworth-Heinemann. • Leeds Demolition. (n.d.). Retrieved October 1, 2015, from http://www. leedsdemolition.co.uk

Foundation • Ching, F., & Adams, C. (2001). Building Construction Illustrated. New York: Wiley. • Chudley, R., & Greeno, R. (2010). Building Construction Handbook (8th ed.). Amsterdam: Butterworth-Heinemann. • Merritt, F., & Ricketts, J. (2000). Building Design and Construction Handbook. New York, NY: McGraw-Hill. • Neufert, E., Neufert, P., & Kister, J. (2012). Architects' Data. Oxford: Wiley-Blackwell. • Tomlinson, M. (1994). Pile Design and Construction Practice. London: E & FN Spon.

89

Superstructure • Merritt, F., & Ricketts, J. (2000). Building Design and Construction Handbook. West Palm Beach, Florida: McGraw-Hill. • Ching, F., & Adams, C. (2001). Building Construction Illustrated. New York: Wiley. • Bassler, B. (2008). Architectural Graphic Standards (11th ed.). Hoboken, N.J.: Wiley. • Tan, E. (1997). Prefabricated Reinforcement Handbook. Singapore: Construction Industry Development Board.

Doors & Windows • Ching, F., & Adams, C. (2001). Building Construction Illustrated. New York: Wiley. • Neufert, E., Neufert, P., & Kister, J. (2012). Architects' Data. Oxford: Wiley-Blackwell. • Advantages of Aluminium Windows and Doors compared to PVC. (2010, December 1). Retrieved October 21, 2015, from

http://www.aluminiumtradesupply.co.uk/22/advantages-of-aluminium-windows-and-doors-compared-to-pvc/ • How to assemble and install an AutoRoll commercial galvanised roller shutter. (n.d.). Retrieved October 20, 2015, from

https://www.youtube.com/watch?v=84QcX-X7Z6A

Roof • Ching, F., & Adams, C. (2001). Building Construction Illustrated. New York: Wiley. • Emmitt, S., & Gorse, C. (2010). Barry’s Introduction to Construction of Buildings (2nd ed.). Oxford: Wiley. • Lysaght. (2014). Zees and Cees User’s Guide: for Design and Installation Professionals. Retrieved October 18, 2015, from

http://www.bluescopesteel.com.au/files/dmfile/LysaghtZedCeesPart1July2014.pdf

90

91

92

93

94

95

96

97

98

99