Modernisation, Mechanisation and Industrialisation of Concrete Structures

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Title:

Physical Description:

xx, 483 pages : illustrations ; 25 cm

ISBN:

9781118876497

Subject Term:

Concrete construction industry

Added Author:

Elliott, Kim S.

Zuhairi Abd. Hamid

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Library	Item Barcode	Call Number	Material Type	Item Category 1	Status
Searching... PSZ KL	33000000011025	HD9622 .A2 M63 2017	Open Access Book	Book	Searching... Unknown

Modernisation, Mechanisation and Industrialisation of Concrete Structures discusses the manufacture of high quality prefabricated concrete construction components, and how that can be achieved through the application of developments in concrete technology, information modelling and best practice in design and manufacturing techniques.

Author Notes

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.

Kim S. ElliottKim S. ElliottKim S. ElliottKim S. Elliott and Zuhairi Abd. HamidThomas Leopoldseder and Susanne SchachingerRobert NeubauerGerhard GirmscheidGerhard GirmscheidJulia SelberherrZuhairi Abd. Hamid and Foo Chee Hung and Ahmad Hazim Abdul RahimZuhairi Abd. Hamid and Poo Chee Hung and Gan Hock Beng

About the Editors	p. xi
Notes on Contributors	p. xiii
Preface	p. xvii
Part 1 Modernisation of Precast Concrete Structures	p. 1
1 Historical and Chronological Development of Precast Concrete Structures	p. 3
1.1 The five periods of development and optimisation	p. 3
1.2 Developing years and the standardisation period	p. 26
1.3 Optimisation and the lightweight period	p. 34
1.3.1 Minimising beam and slab depths and structural zones	p. 34
1.3.2 Orientation rule	p. 38
1.3.3 Composite and continuous floor slabs	p. 38
1.3.4 Composite and continuous internal beams	p. 43
1.4 The thermal mass period	p. 46
1.4.1 Background to fabric energy storage in precast framed and wall structures	p. 46
1.4.2 Admittance and cooling capacity	p. 48
1.4.3 Thermal resistance and U-values for precast ground and suspended floors	p. 51
1.4.4 Conclusion to FES, cooling and thermal transmission	p. 58
References	p. 59
2 Industrial Building Systems (IBS) Project Implementation	p. 61
2.1 Introduction	p. 61
2.1.1 Definition of IBS	p. 63
2.1.2 Advantages of IBS	p. 64
2.1.3 Sustainability of IBS	p. 67
2.1.4 Drawbacks of IBS	p. 68
2.2 Routes to IBS procurement	p. 69
2.2.1 Definitions	p. 69
2.2.2 Preliminaries	p. 70
2.2.3 Project design stages	p. 71
2.2.4 Design and detailing practice	p. 79
2.2.5 Structural design calculations and project drawings	p. 80
2.2.6 Component schedules and the engineers instructions to factory and site	p. 87
2.3 Precast concrete IBS solution to seven-storey skeletal frame	p. 89
2.4 Manufacture of precast concrete components and ancillaries	p. 93
2.4.1 Requirements and potential for automation	p. 93
2.4.2 Floor slabs by slip-forming and extrusion techniques	p. 93
2.4.3 Comparisons of slip-forming and extrusion techniques, and r.c. slabs	p. 102
2.4.4 Hydraulic extruder	p. 102
2.4.5 Reinforced hollow core slabs	p. 103
2.4.6 Automated embedment machines for mesh and fabrics in double-tee slabs	p. 106
2.4.7 Optimised automation	p. 109
2.4.8 Table top wall panels	p. 110
2.4.9 Production of precast concrete wall panels using vertical circulation system	p. 115
2.4.10 Control of compaction of concrete	p. 118
2.4.11 Automation of rebar bending and wire-welded cages	p. 118
2.5 Minimum project sizes and component efficiency for IBS	p. 120
2.6 Design implications in construction matters	p. 120
2.7 Conclusions	p. 122
References	p. 124
3 Best Practice and Lessons Learned in IBS Design, Detailing and Construction	p. 125
3.1 Increasing off-site fabrication	p. 125
3.2 Standardisation	p. 133
3.3 Self-compacting concrete for precast components	p. 137
3.4 Recycled precast concrete	p. 142
3.5 Building services	p. 144
3.6 Conclusions	p. 147
References	p. 147
4 Research and Development Towards the Optimisation of Precast Concrete Structures	p. 149
4.1 The research effort on precast concrete framed structures	p. 149
4.1.1 Main themes of innovation, optimisation and implementation	p. 149
4.1.2 Structural frame action and the role of connections	p. 151
4.1.3 Advancement and optimisation of precast elements	p. 156
4.1.4 Shear reduction of hcu on flexible supports	p. 157
4.1.5 Continuity of bending moments at interior supports	p. 159
4.1.6 Horizontal diaphragm action in hollow core floors without structural toppings	p. 160
4.2 Precast frame connections	p. 162
4.2.1 Background to the recent improvements in frame behaviour	p. 162
4.2.2 Moment-rotation of beam to column connections	p. 162
4.2.3 Research and development of precast beam-to-column connections	p. 167
4.2.4 Colunm effective length factors in semi-rigid frames	p. 170
4.3 Studies on structural integrity of precast frames and connections	p. 170
4.3.1 Derivation of catenary tie forces	p. 170
References	p. 173
Part 2 Mechanisation and Automation of the Production of Concrete Elements	p. 177
5 Building Information Modelling (BIM) and Software for the Design and Detailing of Precast Structures	p. 179
5.1 Building information modelling (BIM)	p. 179
5.1.1 Introduction	p. 179
5.1.2 History and ideas	p. 180
5.1.3 Types of BIM	p. 183
5.1.4 BIM around the world	p. 185
5.1.5 BIM and precast structures	p. 187
5.2 Technologies	p. 188
5.2.1 Industry foundation classes (IFC)	p. 188
5.2.2 IFC data file formats and data exchange technologies	p. 192
5.2.3 BIM model software	p. 195
5.3 BIM in precast construction	p. 198
5.3.1 Project pricing for precast structures based on 3D models	p. 198
5.3.2 Technical engineering	p. 198
5.3.3 Production data and status management	p. 202
5.3.4 Logistics, mounting, and quality management	p. 206
5.4 Summary	p. 207
References	p. 207
6 Mechanisation and Automation in Concrete Production	p. 210
6.1 Development of industrialization and automation in the concrete prefabrication industry	p. 210
6.1.1 Stationary flexible forms, tables and formwork in a prefabrication plant	p. 211
6.1.2 Long-bed production	p. 213
6.1.3 Pallet circulation plant	p. 217
6.1.4 CAD-CAM: the path to automation	p. 221
6.2 CAD-CAM BIM from Industry 2.0 to 4.0	p. 224
6.2.1 Production of non-variable parts versus production in lot size one	p. 224
6.2.2 IBS - suitable prefabricated products for mechanization and automation	p. 227
6.2.3 Just-in-time planning and production using ERP systems	p. 234
6.2.4 MES systems for mechanization and automation	p. 238
6.3 Automation methods	p. 242
6.3.1 From simple to the highly sophisticated	p. 243
6.3.2 Automation methods	p. 243
6.4 Integrated and automated prefabricated production process	p. 286
6.4.1 Structures	p. 287
6.4.2 ERP, CAD, MES, PROD machines, HMI	p. 289
6.4.3 HMI - integrating staff into the process	p. 289
6.4.4 Smart factory, industry 4.0 - integration into BIM	p. 291
6.4.5 QM included	p. 293
6.5 Limits of automation	p. 298
6.5.1 Labour cost versus automation	p. 298
6.5.2 Costs, necessary skills and ROI	p. 298
6.6 Summary and outlook	p. 300
Part 3 Industrialisation of Concrete Structures	p. 301
7 Lean Construction - Industrialisation of On-site Production Processes	p. 303
7.1 Work process planning (WPP)	p. 304
7.1.1 Construction production planning process - introduction	p. 304
7.1.2 Construction production process - principles and sequence	p. 310
7.1.3 Systematic basic production process planning - steps	p. 311
7.1.4 Continuous construction process management	p. 313
7.2 Construction production process planning procedure	p. 314
7.3 Work process planning (WPP) - work execution estimation	p. 322
7.4 Work process planning (WPP) - planning the processes and construction methods	p. 329
7.5 Planning the execution process	p. 332
7.6 Procedure for selecting construction methods and processes	p. 336
7.6.1 Objectives when comparing construction methods	p. 336
7.6.2 Methodological approach to comparing construction methods	p. 338
7.7 Conclusions to Chapter 7	p. 343
References	p. 344
8 Lean Construction - Industrialisation of On-site Production Processes	p. 346
8.1 Introduction - top-down / bottom-up work planning scheduling and resource planning	p. 347
8.2 Scheduling and resource planning	p. 348
8.3 Site Logistics	p. 352
8.3.1 Logistics planning	p. 352
8.3.2 Transport logistics	p. 354
8.3.3 Delivery, storage and turnaround logistics	p. 355
8.3.4 Planning storage areas - storage space management	p. 356
8.3.5 Disposal logistics	p. 357
8.4 Weekly work plans	p. 357
8.4.1 Lean construction - weekly work program	p. 357
8.4.2 Equipment and material call-up	p. 384
8.4.3 Organizing the construction workflow, construction methods, and health and safety	p. 390
8.5 Construction site controlling process	p. 391
8.5.1 Performance specifications	p. 391
8.5.2 Controlling weekly work performance	p. 393
8.6 CIP - the continuous improvement process	p. 398
8.7 Conclusions	p. 401
References	p. 403
9 New Cooperative Business Model - Industrialization of Off-Site Production	p. 404
9.1 Introduction	p. 405
9.2 Objectives of the new business model	p. 406
9.3 Modelling	p. 408
9.3.1 Formal structuring	p. 408
9.3.2 Contextual configuration of the outside view: development of the new service offer	p. 409
9.3.3 Contextual configuration of the inside view: Realization of the value creation process	p. 409
9.3.4 Overview	p. 420
9.4 Conclusion	p. 420
References	p. 421
10 Retrospective View and Future Initiatives in Industrialised Building Systems (IBS) and Modernisation, Mechanisation and Industrialisation (MMI)	p. 424
10.1 Industrialisation of the construction industry	p. 424
10.2 Overview on global housing pre fabrication	p. 426
10.3 Housing prefabrication in Malaysia - the industrialization building system (IBS)	p. 427
10.3.1 Chronology of IBS development in Malaysia	p. 429
10.3.2 IBS roadmap	p. 433
10.3.3 IBS adoption level in Malaysia	p. 435
10.4 Social acceptability of IBS in relation to housing	p. 439
10.5 IBS in future - opportunity for wider IBS adoption	p. 443
10.5.1 Greater Kuala Lumpur	p. 444
10.5.2 Affordable housing	p. 446
10.6 Conclusion	p. 450
References	p. 450
11 Affordable and Quality Housing Through Mechanization, Modernization and Mass Customisation	p. 453
11.1 Introduction	p. 453
11.2 Design for flexibility - insight from the vernacular architecture	p. 457
11.3 Scope of flexibility in residential housing	p. 459
11.4 Divergent Dwelling Design (D3) - proposed mass housing system for today and tomorrow	p. 461
11.5 Design principles of D3	p. 464
11.5.1 The design of the unit plan	p. 465
11.5.2 Unit configurations design	p. 466
11.5.3 Sustainable strategies design	p. 467
11.5.4 Structure and construction design	p. 468
11.6 Conclusion	p. 472
References	p. 473
Index	p. 475

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