BUILDABLE SOLUTIONS FOR LANDED RESIDENTIAL DEVELOPMENT IN SINGAPORE Lowres PDF
BUILDABLE SOLUTIONS FOR LANDED RESIDENTIAL DEVELOPMENT IN SINGAPORE Lowres PDF
BUILDABLE SOLUTIONS FOR LANDED RESIDENTIAL DEVELOPMENT IN SINGAPORE Lowres PDF
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Whilst every effort has been made to ensure the accuracy of the information contained in this
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BUILDABLE
SOLUTIONS
FOR
LANDED
RESIDENTIAL
DEVELOPMENT
IN
SINGAPORE
CONTENTS
Page
ACKNOWLEDGEMENT
Chapter 1 INTRODUCTION 1
APPENDIX 146
ACKNOWLEDGEMENT
Name Organisation
Special thanks are due to the following who have contributed their photographs,
drawings, details and material for the handbook
Name Organisation
Landed residential developments tend to have the lowest site productivity amongst
the different types of developments. In Singapore, these types of developments
consistently form a significant proportion of the total number of private residential
projects built every year. In the recent years, landed residential projects made up
about 80% of the total number of private residential projects awarded per year
although landed properties form only about 20% of the total housing supply. This
situation will negate measures to improve the overall industry productivity. Hence, it
is essential to provide a design solution for small landed residential developments
A study has been carried out to develop and document a few simple, flexible,
innovative and buildable systems suitable for small landed residential developments.
The key objectives of the studies were to identify buildable systems that are able to
improve site productivity, construction quality, minimize plastering works and
minimize wastage due to re-works. These buildable systems are:
• Precast system
• Flat plate system
• Structural steel system
• Light gauge steel frame system
With the use of these buildable systems, especially having some of the components
built or cast off-site, wet site works will be reduced, thus leading to improvement in
site safety. These buildable systems have proven to be capable of providing
significant design flexibility, without significant increase in cost whilst offering early
delivery of houses to the homeowners.
1
Examples of projects constructed using prefabricated systems
Designed by S H Lim Architects Pte Ltd and Resources + Planning Design Consultants
Features
Benefits
2
2 storey semi-detached dwelling house with a roof terrace at Seletar Hills Drive
Features
Benefits
3
2 storey semi-detached dwelling houses with attic at Tavistock Avenue
Features
Benefits
4
2-storey in-fill terrace with pitch roof at Jalan Batai
Features
Benefits
5
3 storey semi-detached house with pitch roof at Upper Changi Road East
Features
• Light gauge steel frame with fibre
cement board for walls and slabs
Benefits
Designed by A-Alliance
6
Examples of completed projects using prefabricated embellishments
Features
Benefits
• Reduce construction duration with
wall installation and roofing
• Reduce dead load on structures
7
2 storey detached house with metal roof at Maple Avenue
Features
• Prefabricated metal
louvers as facade
walls
• Prefabricated steel
staircase
• Metal roof
Benefits
• Reduce construction
time for roof &
louvers
• Maximisation of
space at staircase
area
8
2 storey detached house with flat roof at Berrima Road
Features
Benefits
• Quick to assemble
• Greater accuracy
• Achieve clean edges and lightweight appearance
9
2 storey detached house with flat roof at Victoria Park Road
Designed by WOHA
Photograph by Tim Griffith & Albert Features
Lim K S
• Steel staircase with prefabricated stair treads
• Prefabricated timber louvers facade
• Glass facade with steel stiffeners
• Glass parapet
• Modular size of columns
Benefits
10
New erection of a 2 storey bungalow at
Bowmont Gardens
Features
Benefits
Features
Benefits
Designed by HYLA
11
Additions & Alterations to a 2 storey
end terrace house at Kee Choe
Avenue
Features
Benefits
Designed by HYLA
Features
Benefits
• Easy to install
• Access to light and external sun-shading
blinds
Designed by HYLA
12
New erection of a 2 storey semi-
detached dwelling house at Jalan
Sedap
Features
Benefits
Designed by HYLA
13
Chapter 2 SELECTION AND DESIGN OF HOUSES
USING BUILDABLE SYSTEMS
2.1 DESIGN CONSIDERATIONS
The design of any project should suit the purpose of use and the building type, i.e.
residential development, institutional development etc. For a project involving any
prefabricated system, the designer should seek solutions which maximize the
beneficial aspects of the system, resulting in optimum buildability and economy.
Project 1 - Option A
14
Designed by RSP Architects, Planners & Engineers (Pte) Ltd
15
• TRODU
Project 2 - Option A
• Timber cladding to
dry external walls
• Stone cladding to
part of elevation
• Metal roofing for
pitch roof
Project 2 - Option B
16
Project 3 - Option A
• Metal cladding to precast walls or dry
walls of covered patio
• Groove line expressed along the joints of
the precast facade walls
• Off-formed groove patterns to rear precast
wall
• Metal cladding to gable end facade wall
The following highlights some of the general details that need to be considered with
regard to design:
17
2.2 SITE CONSIDERATIONS
Figure 2.1 Use of 50-tonne crane for Figure 2.2 Hoisting of precast facade
hoisting
Figure 2.3 Assembly of steel elements in Figure 2.4 Use of lorry crane for lifting of
position steel elements
18
2.3 COSTING
It is important to note that many factors affect the cost of a project. Apart from direct
material costs, factors such as construction time, scale of project, labour components,
expected quality, and even external micro economic conditions all affect the overall
cost of a project. It is therefore difficult to do a simple direct material cost comparison
without also understanding the other affecting factors in the cost analysis.
The construction cost may be further broken down into the following:
Percentage of costing
per house
Preliminaries 5 - 10%
Foundation 5 - 10%
Structural works 20 - 30%
Architectural works 40 - 45%
M&E works 10 - 30%
External works 3 - 5%
19
The project team has reviewed the elemental cost for comparison of precast
design with conventional design. The increase in the cost of precast design is
found to be minimal as shown below:
*The prices below are indicative only and may differ from time to time and from different
contractors and precasters. It is recommended that developers and designers consult
precasters and contractors in the actual pricing of the projects.
*The cost comparison is only on components which were replaced by buildable systems.
20
Material costs, of which precast components form a significant part of, cannot
and should not be evaluated independently of other cost related factors.
Otherwise, the comparison would be misleading. For example, by using more
expensive precast construction, direct labour costs are reduced. This is a
significant consideration in a market like Singapore where labour cost has been
and is expected to continue rising. Time saving is another important factor, and
this translates directly to lower preliminaries and faster project turnover. On the
other hand, the benefits of improved quality are appreciable but difficult to
measure. Better quality means lower subsequent defect rectification costs, but its
direct cost benefit is not as easily quantifiable.
21
to bungalows and large detached houses or houses sited in unusual land
configuration, precast construction is probably not a cost-effective solution.
On the other hand, for the majority of terrace houses or semi-detached
houses, whether in new development, in-fill development or addition &
alteration, the general design will typically fall within a certain fixed framework
where precast will be a competitive solution. There is sufficient flexibility in the
precast system for architects and engineers to still exercise his imagination
and creativity.
4. Risks & Time Factor – Part of the reason for the current higher costs in
precast construction is due to perceived risk factors applied by contractors. A
typical small house contractor is not likely to be as familiar with precast
construction as compared to larger contractors. Unknown factors contribute
to risks and higher costs. It is fair to assume that with gradual and eventual
familiarisation with precast construction methodology, the learning costs for
contractors and the unknown risk factors will be reduced over time. This
would in the long run lead to lower and more realistic costs for precast
construction.
22
Chapter 3 DESIGN CONCEPT FOR PRECAST SYSTEM
• Conventional foundations comprising footings, raft slab or piles and pile caps.
• Cast in-situ first storey, typically reinforced concrete beam and slab system.
• Precast concrete load bearing walls.
• Precast concrete non-load bearing façade panels.
• Precast concrete floor system, either:
- Precast concrete beams and precast slabs (reinforced concrete or
prestressed) with a composite in-situ topping
or Precast concrete walls with precast concrete slab system
Figure 3.1 Precast prestressed slabs spanning between walls with composite in-situ
topping for 1st storey
23
Figure 3.2 Precast prestressed slabs spanning between walls with composite in-situ
topping for 2nd storey
Figure 3.3 Precast prestressed slabs spanning between walls with composite in-situ
topping for 3rd storey
24
Figure 3.4 Precast prestressed slabs spanning between walls with composite in-situ
topping for roof
25
3.2 FOUNDATIONS
Precast wall
The foundation loads for the precast Grout
structural system will be similar to those
for conventional design. However, the
arrangement of the foundations below the
load bearing walls will be different to
those normally adopted for a column and
beam structural system. The desirable
arrangement should provide a relatively
uniform support along the length of the
wall and minimize the eccentricity effects
due to any possible misalignment of the
walls relative to the foundations. Ground beam
and slab
In the case of a footing foundation
system, the recommended solution is a
continuous strip footing below the load Footing
bearing walls, as shown in Figure 3.5.
Similarly, a raft foundation system, as shown in Figure 3.6, will provide a uniform
support to the load bearing walls and excellent resistance to eccentricity effects.
For a piled foundation, uniform support along the full length of the wall can be
provided by adopting piles at closer spacing with a first storey capping beam. This
solution is unlikely to be economical. The recommended approach is shown in Figure
3.7, which is based on the following structural concept:
• Within the precast concrete wall, zones are designated as load bearing and non-
load bearing.
• Piles are located below the load bearing zones only.
• The first storey beam is used to disperse the pile support along the wall, but is not
designed as a capping beam.
• The piles are preferably provided in groups of two or more, located on each side of
the wall centerline. If single piles are necessary, first storey beams are required in
the transverse direction to accommodate any possible eccentricity effects.
26
Precast wall Load
bearing
Grout joints
within PC
walls
Strip footing
Loads transfer through 1st sty
beams
Figure 3.6 Precast load bearing wall on strip Figure 3.7 Precast load bearing wall on
footing or raft foundation piled foundation
Adopting conventional construction for the first storey has the additional advantage of
providing more lead time for the production of the precast components. However, it is
also possible and sometimes advantageous to use a precast system for the ground
beams and slab.
27
3.4 PRECAST LOAD BEARING WALLS
Precast load bearing walls provide an economical solution when compared to the
conventional column/ beam/ infill wall system. The primary advantages are speed of
construction and elimination of wet trades.
To minimise the requirement to lap vertical bars, the walls are recommended to be
designed as plain concrete members in accordance with CP65 3.9.4.
In adopting the wall thickness, structural adequacy is not the sole consideration.
Other factors to be considered include:
• Connection details for supported beams and slabs.
• Sound transmission and fire rating.
• Joint details at panel-to-panel connections.
• Possible future embedded services, which could reduce the concrete area
available.
Based on typical layouts and building configurations, a thickness of 180mm is
recommended for the precast panels used for party walls.
28
3.4 b Corner Terrace and Semi-Detached Houses
For corner terrace and semi-detached units, the external side wall is required to be
load bearing. In this case, the panel design will be influenced by factors such as:
In some cases, plain concrete design may be applicable. However, it may usually be
necessary to adopt reinforced concrete design with continuity of vertical bars in these
load bearing walls. For these walls, the recommended thickness is 150mm.
29
3.5 PRECAST NON-LOAD BEARING FAÇADE PANELS
Typically, the wall panels for the front and rear elevations are non-load bearing façade
elements. Support of these panels is achieved by any of the following methods:
• The façade panel is connected to main load bearing walls and is designed to
carry its own weight between supports.
• The façade panel is connected to the floor slab or beam, which is then
designed to provide support to the wall.
These panels will typically be designed for vertical loads due to self weight and an
allowance for floor loads, if applicable, in addition to horizontal loads due to external
wind pressures. A typical panel thickness of 120mm is proposed on the basis of
strength considerations and to accommodate window fixings and profiles around the
window perimeter.
30
Façade panels will often require three-dimensional architectural features, such as
hoods, sills and ledges. In cases where there is a reasonable degree of repetition,
customised moulds can be produced, enabling these features to be economically
incorporated into the panels. As an alternative, when repetition is limited, it will be
most economical to cast the façade panel flat and subsequently add the features,
manufactured separately using materials such as precast concrete, GRC, Aluminium
or steel.
The location of joints between external wall panels should be selected based on
careful consideration of the following factors:
• Structural Considerations
External wall panels may be load bearing (e.g. side walls of corner terrace,
semi-detached or detached) or non load bearing (e.g. front and rear façade
panels). In selecting panel joint locations, it is important to consider the panel
stability (i.e. ability to resist horizontal loads such as wind pressure or loads
specified in the Building Regulations Fourth Schedule).
• Aesthetics
Whilst in general, panel joints are not highly visible, locations should be
selected which minimise any potential impact on the external façade aesthetics.
In general, vertical joints should align for the full height of the building and
would preferably be located symmetrically with respect to adjacent features.
• Panel Weight
The weight of panels will dictate the crane capacity required for installation of
the wall panels. Apart from the disadvantage of higher cost, larger capacity
cranes may not be able to access the site. For typical conditions, a weight
limitation of approximately 4 tonnes is considered likely to be applicable. In
general, the panel size should be maximized, leading to increased speed of
construction and reduced number of panel joints to be treated.
• Transport Limitations
For transportation purposes, it is necessary to limit one of the panel dimensions
to 3.6m. In general, panel heights will be less than 3.6m and panel length is
based on weight or other considerations. When the required panel height
exceeds 3.6m, the length of panel will be reduced to 3.6m or less. Early
planning for site access must be undertaken, particularly when houses are built
along Category 5 road.
31
• Internal Crack Control
To minimise the risk of cracks appearing at the internal face of wall panel joints,
the following considerations are relevant:
- If possible, locate panel joints at internal wall intersections, inside service
ducts or wardrobes and at other non-visible locations.
- Avoid panel joints towards midspan of floors, where beam or slab
deflections could lead to joint opening.
- Avoid long continuous runs of panels, where accumulated shrinkage could
result in joint cracking.
An effort has been made to develop a standardised approach for the precast panel
profile at window openings. The proposed detail is considered suitable for precasting
and can be applied for the majority of projects.
Refer to Figure 3.10 and Figure 3.11 for the proposed precast panel profile at window
openings.
32
Alum.
window
extrusion is
indicative
only
Figure 3.11 Opening for Window at precast Figure 3.10 Opening for Bay window
facade wall
33
3.6 PRECAST FLOOR SYSTEM
Two alternate floor systems have been developed for the proposed precast system.
Services within the bathroom and toilet floors are generally of significant diameter and
required to be laid to fall. In these areas, it is likely that a minimum topping thickness of
85mm would be necessary to incorporate these services. Assuming that the slab soffit is
flat, to limit the total slab thickness for the floor adjacent to the bathroom, it is encouraged
to limit to only one drop of 50mm at the wet areas. For shower areas, it is recommended
to have kerb instead of a second drop to avoid thickening the slab at non-drop area.
3.6 a Floor System Alternate 1 - Prestressed Plank and Half-Slab Floor System
This precast floor system (refer to Figure 3.12), comprises prestressed planks spanning
between load-bearing walls. Where voids, stairs and other features prevent the slabs from
spanning between walls, slabs spanning perpendicularly are provided, supported by the
adjacent planks.
34
Figure 3.12 Typical floor layout for precast walls with precast slab
35
3.6 b Floor System Alternate 2 - Precast beams and precast slabs
This precast floor system (refer to Figure 3.13) comprises RC half-beams spanning
between load bearing walls and half-slabs spanning between beams.
However, other factors to be considered for the precast beam and slab floor system are:
• Beam penetrations will often be required for M&E services. These will require
significant co-ordination and are technically difficult for the half beam system.
• Beam connections to supporting walls are preferably via wall pockets. The pockets can
become deep when floor levels between adjacent units vary significantly.
Figure 3.13 Typical floor layout for precast walls with precast beams and precast slab
36
3.7 Connection details
Figure 3.14 Joints at party wall and Figure 3.15 Layout plan for precast wall with
connection between prestressed precast planks (with section
party walls and facade marking)
walls
37
3.7 b Treatment of Joint for non-load bearing facade panels
For vertical joints, a wet pour of grout / 9mm aggregate mix is provided as a
waterproofing backup and to assist with crack control on the internal face.
An important consideration with the proposed details is continuity of sealant.
Options are given for façade to party wall, depending on whether party wall is
exposed or hidden. Selection of the appropriate detail will depend on
considerations of layout, appearance and whether the adjoining units are
staggered horizontally.
Recommended jointing details as shown in Figure 3.16 to Figure 3.22.
38
Figure 3.19 Option A - Plan of Figure 3.20 Option A - Plan of
connection between end wall and connection between party wall and
facade wall facade wall
Figure 3.23 Section of pour strip for Figure 3.24 Section of slab with change in
precast slab slab thickness
Figure 3.25 Section of pour strip with Figure 3.26 Section of pour strip with top
additional bars for slab support drops for slabs
40
Figure 3.27 Section of slab details to Figure 3.28 Section of slab details to party
facade walls walls
41
3.8 M&E SERVICES
In this option, the horizontal services need to be embedded either in the slab
topping or the precast plank itself and the vertical element is embedded in the
precast wall. Co-ordination work is quite extensive, as all M&E services inside
individual precast panels or planks need to be pre-planned and pre-determined
beforehand. In particular, the interface between the horizontal and vertical
element needs to be co-ordinated to ensure that they coincide exactly.
Another consideration is that precast panels are usually thinner than conventional
brick and plastered walls. Hence, it is important to ensure that all services are
accommodated without affecting the structural integrity of the panel.
Technical Details
A. Electrical Services
• Provide connection ring for ceiling light points at precast plank. Connection of
junction boxes and conduits to be embedded in the slab topping on site with
200mm by 200mm pockets for connection to vertical element.
• Provide cast-in conduit/KO boxes in precast wall panel for switches/wall light,
with 200mm by 100mm pockets at top/bottom for switches/wall light points for
connection to horizontal element.
42
• Horizontal conduits for power/SCV/telephone to be embedded in slab topping
with pockets provided for connection to vertical element.
• Provide appropriate size groove of 40mm depth at precast wall panel for
installation of vertical conduits and KO boxes.
• All pockets and grooves to be patched back with structural grout after
completion of installation and connection.
• Provide 75mm width by 40mm depth groove for concealed hot & cold water
piping in precast wall panel.
• Provide 75mm width by 50mm depth groove for concealed basin/sink waste
vertical pipes in precast wall panel.
• Minimum topping of 90mm is required for concealing the horizontal waste
pipes in the topping with a 250mm by 300mm box-out for the floor trap and
150mm by 150mm box-out for floor waste at the bathroom precast plank.
• Horizontal waste pipes to be embedded within the topping together with the
floor trap and floor waste and cast together.
• All pockets and grooves at wall panel to be patched back with structural grout
after completion of installation and connection.
C. ACMV Services
• Provide cast-in condensed drain pipes with insulation in the precast wall panel
with 150Wx300Hx75D mm groove at bottom and 150Wx500Hx75D mm
groove at top for connection and refrigerant pipes at fan coil location.
• Provide individual condensate pipes dropper to ground floor for connection to
drain or floor trap at ground floor.
• Provide 75Wx25D mm groove at precast plank between fan coil unit and
condensate pipes dropper for horizontal condensed pipes to ensure good
gradients.
• Horizontal condensed pipes to be embedded within the topping with 200mm
by 150mm pocket for connection to vertical element.
• All pockets and grooves at wall panel to be patched back with structural grout
after completion of installation and connection
Pre-planning of all M&E services in the precast plank and wall is critical in
ensuring that the horizontal and vertical elements can be joined easily and the
installation works can be carried out smoothly. The following provides a guideline
for the co-ordination of M&E services in a precast development.
• All M&E services routing and installation procedure must be confirmed before
commencement of precast operations.
43
• All precast panels need to be confirmed and individually named to ensure that
the location of each panel can be determined correctly during launching.
• Precast Geometry Drawing must be produced by the precaster (including
layout plans) and issued to the M&E contractor for him to incorporate the M&E
services into the precast panels before commencing precast production.
• Main contractor to incorporate individual services into a combined services
geometry drawing for construction.
Figure 3.29 Option 1 - Services laid within the cast in-situ topping over the PC
slab
44
Figure 3.30 Option 1 - Proper co-ordination at interface between horizontal vertical
element
45
3.8 b Option 2 – External Tray
Instead of embedding all M&E services within the precast panels, this option
makes use of an external tray / ring system. There are a number of additional
advantages to this system (in comparison to the previous option). Whilst good
planning is still essential, the option here reduces the extent and degree of pre-
planning required. It will no longer be necessary to plan and ensure that M&E
services are properly accommodated within the panels to prevent any adverse
impact on structural integrity. Instead, there will be additional flexibilities for
changes or additions of M&E services.
Technical Details
All M&E services are housed together in an external tray which is mounted on the
wall / ceiling surface. Architectural treatment such as a false ceiling or a bulkhead
would be used to conceal these services. A typical bulkhead is shown in the
attached drawings. In a worse case scenario, a bulkhead of up to 400mm would
be needed. This would generally not be an issue as the clear floor height of a
typical landed house would be in excess of 3 metres.
Horizontal lines are installed on top of the precast floor slab at site. These
services would be concealed in the concrete topping layer later.
46
450
400
200
47
Chapter 4 CONSTRUCTION METHOD FOR PRECAST
SYSTEM
The main factor that contributes to the success of a precast building project is
‘integration’ of all building professionals. Professionals stated here include architects,
engineers, clients, contractors and sub-contractors. The involvement of all players at
an early stage is critical to a precast project.
Very often, contractors are tasked to convert a traditional cast in-situ (Architectural
and Structural) design to a precast design. The design development will involve
modification to the consultants’ design intent. As such, it is not uncommon for the
contractor to face strong resistance from the consultant team. This is to be predicted
as any player tends to be defensive if his ‘professional’ views are being challenged.
Today, the fragmentation approach towards design and construction among the
professionals within a project is evident in most projects. A shift in paradigm is crucial
to achieve success in any project. This section attempts to provide a guide for the
construction of a precast project. The reader should refine the contents by
consultation with professionals and precasters.
• All safety issues on site when handling precast elements, especially so when
working within a tight site
• The lifting capacity of the crane used
• The working boom-radius of the crane
• The suitability of construction materials for the purpose of use, i.e. sealant,
grouting, shim plate, propping etc
• Co-ordination with the precaster and specialist supplier to achieve the best
performance and working method - precaster often provide relevant technical
requirements to the contractor during the design development phase to avoid
discrepancy
48
Figure 4.1 Precast walls are propped before Figure 4.2 The pour strip between 2 pieces of
casting of joints – proper planning precast walls are cast
is required for perfect alignment
Figure 4.3 Precast planks are installed in Figure 4.4 Preparation for casting of
place landing slab to precast
staircase
49
4.2 SEQUENCE OF WORK
A Quick Check
Construction Requirements
• Elements of control
• Tolerance level
1. For Wall
• Vertical deviation +2 mm, -2 mm
• Horizontal deviation 0 mm
50
The diagrams below illustrated the sequence of installation for the precast beam-slab
system:
The Procedure
• Setting Out
• Wall Positioning
51
• Wall Adjustment
52
• Slab Setting Out II
• Staircase
53
Precaution
2. Alignment Priority
• Alignment of grooves.
• Uniformity of grooves.
• Horizontality of architectural treatment ie. Brick Tile
Post Installation
54
4.3 CONSTRAINTS AND SOLUTIONS
4.3a Access
CONSTRAINTS SOLUTIONS
Small road in front of site may not Use smaller crane and trailers to
allow crane and delivery trailers deliver and install small
up to 3.5m wide to park. components.
Crane and trailer are unable to Study the locality and look for
negotiate small turning radius at available space for turning. Have
junctions of small roads. one worker direct traffic while crane
and trailer is turning.
55
4.3b Crane Capacity and Reach
CONSTRAINTS SOLUTIONS
Lifting capacity of small crane not Hire bigger crane with longer boom
enough to lift heavy and far to lift heavy and far components.
components. Alternatively, plan the sequence
such that the crane can park nearer
to the heavier components.
4.3c Coordination
CONSTRAINTS SOLUTIONS
4.3d Installation
CONSTRAINTS SOLUTIONS
Lifting over neighbour’s roof may Crane and trailer can be parked
cause anxiety over safety and strategically to avoid such lifting.
damage to existing properties. Crane operator can make use of
boom angle to keep lifting within
site boundary.
4.3e Handling
CONSTRAINTS SOLUTIONS
56
Figure 4.7 Optimisation of crane usage (50 tonne crane) and weight of components
57
Chapter 5 DESIGN CONCEPT FOR FLAT PLATE
SYSTEM
5.1 STEEL/ CONCRETE COLUMN WITH FLAT PLATE SYSTEM
With increasing demand for flexibility in interior layout, the use of flat plate for landed
houses is gaining much popularity amongst architects. The main and unique feature
of this system is that it provides a way for the architect to achieve the concept of high
and completely flat ceiling with no beam protrusion.
Some projects have reported an improvement in the construction speed and cost
savings from using this system which requires only simple formwork. The use of flat
plate appeals to designers particularly because design flexibility is possible through
shifting of walls without the need for columns to be properly aligned. The services can
be installed within or below the slab and there are flexibilities in relocating vertical
small penetrations. The soffit is often flat and high ceiling height can be achieved.
The columns used in this system are either cast in-situ concrete columns or circular
steel hollow sections. When the columns used are steel hollow sections with
concrete in-fill, the desired finish with exposed steel can be easily achieved.
58
5.2 CONNECTION AND DETAILING
The main consideration for steel column connection to flat plate is to ensure that the
base plate for the steel columns are cast into the concrete flat plate. Hence the
positioning and alignment of the base plates are of utmost importance.
If concrete in-fill and column bars are required within the steel hollow section, the
starter bars for the columns have to be placed and fixed in position prior to casting of
concrete flat plate (see figure 5.5 for base plate connection).
In the concrete column with flat plate design, the connection is more simplified without
the need for base plate connection. In this case, reinforcement bars should be
properly detailed between the columns and slabs. Punching shear checks are critical
and vertical shear reinforcement should be detailed accordingly.
59
Figure 5.2 Typical shear failure near column. Proper detailing of shear reinforcement
must be provided
60
Alternatively, designers may introduce hidden beam within slab along column strip to
cater for the shear stresses near column location.
Figure 5.4 Hidden beam within column strip Figure 5.5 Base plate details for column
Figure 5.6 Semi-detached houses using flat plate with steel column (near completion)
Designed by: IP:LI Architects
61
Chapter 6 CONSTRUCTION METHOD FOR FLAT
PLATE SYSTEM
6.1 GENERAL CONSIDERATIONS
The following are the key factors to be considered before adopting the use of the
concrete flat plate with steel/concrete column system:
• Architectural layout should be well planned to fully enhance the main area
where high flat ceiling with neatly arranged steel/concrete columns are
required in the design
• Spacing of columns
• Early planning of routing for M&E services, opening for voids and location of
staircase
With the use of flat plate system, no complicated formwork is needed for beams.
The formwork for slab can be recycled with repetition in floor layout. The use of
prefabricated reinforcement for slab is recommended to achieve higher
productivity on site.
Figure 6.1 Construction of circular steel hollow section with cast in-situ flat plate
62
Figure 6.2 Flat ceiling with ease in formwork installation
63
Flat plate system with circular columns
64
Flat plate system with circular columns
65
Chapter 7 DESIGN CONCEPT FOR STRUCTURAL
STEEL SYSTEM
7.1 STRUCTURAL STEEL SYSTEM
- Steel column/ beam/ metal deck
The building vertical design loads comprise of the dead weight of the structure
and the live loads. The secondary steel universal beams are spaced to support
the composite slab such that during casting, no additional props are required.
The main steel beams support the secondary beams and transfer load to the
columns. The composite slab with its welded mesh form horizontal ties. The
composite slab laterally restrains the beams.
Columns can be in the form of steel hollow section columns with concrete in-fill or
steel H-sections with fireproofed box-up to provide for a half-hour fire rating
resistance.
All exposed steel members are to be painted with approved coating e.g. zinc
chromate primer prior to two coats of enamel paint.
17 Tavistock Ave
Designed by LOOK Architects
66
7.2 CONNECTION AND DETAILING
Column to Foundation
The base connections should be designed as pin joints. Bolts can be cast
together with the stump. Base plates are to be bolted and leveled with non-
shrink grout. Steel columns are to be lowered and welded to base plate.
Column to column
Splice connection between steel columns can be butt welded with splice plates.
Figure 7.1 Connection details 1 (details and sizes shown are indicative only)
67
Figure 7.2 Connection details 2 (details and sizes shown are indicative only)
Figure 7.3 Typical section of composite slab (details and sizes shown are indicative
only)
68
Figure 7.4 Slab details (details and sizes
shown are indicative only)
69
Figure 7.7 Connection details for 50mm drop in slab (details and sizes shown are
indicative only)
Figure 7.8 Connection details for 100mm drop in slab (details and sizes shown are
indicative only)
70
Treatment of M&E services
The openings in the webs and stiffeners are to allow for during fabrication of steel
beams in factory, as these elements are to be hot-dipped galvanized. They require
early planning of M&E services in the preliminary design stage.
71
Figure 7.10 3-D graphic presentation of steel frame
72
Chapter 8 CONSTRUCTION METHOD FOR
STRUCTURAL STEEL SYSTEM
Figure 8.1 Erection of steel column and beams - Temporary bracing was
required to ensure verticality of steel columns when bolt connections from beams
to columns were tightened.
73
Figure 8.2 Bolted connection for column to beam with laying of metal decking for
second storey and roof
Figure 8.3
Installation of precast facade walls to beams
74
Chapter 9 STRUCTURAL CONCEPT FOR LIGHT GAUGE
STEEL FRAME SYSTEM
9.1 BACKGROUND
Over the years, various improved systems have been developed for use in landed
properties. An economical light gauge steel frame system is increasingly being used in
America, Europe, Australia and New Zealand. This light gauge steel frame is developed
through a cold-formed process without the use of heat. This process enables steel
manufacturers to produce light-weight but high tensile steel sheets. The sheet surface is
coated with a zinc alloy that completely covers the steel surface and seals it from the
corrosive action of its environment. This results in buildings that are more solid, rigid,
stronger, durable and easier to build.
As such, the light gauge steel frame system is an attractive alternative for use in landed
properties. This is particularly in view of concerns on the depletion of timber resources and
low productivities associated with reinforced concrete construction.
75
Completed house at Upper Changi Road East
76
9.2 WHY USE LIGHT GAUGE STEEL FRAMING SYSTEM
Benefits
Quality: A better quality finished house that is durable and low in maintenance.
Design Flexibility: Because of its strength, steel can span longer lengths,
offering larger open spaces and increased design flexibility without requiring
intermediate columns or load bearing walls.
77
9.3 STEEL FRAMING LANGUAGE
78
Gauge: A unit of measurement coatings. Thickness is expressed in
traditionally used to describe the mils (traditionally expressed in
nominal thickness of steel. The lower gauge).
the gauge, the greater the thickness.
Mil: A unit of measurement typically
Header: A horizontal built-up used in measuring the thickness of
structural framing member used over thin elements. One mil equals
wall or roof openings to carry loads 1/1000 of an inch.
across the opening (See Figure 9.1).
Multiple Span: The span made by a
In-Line Framing: Frame systems continuous member having
where all vertical and horizontal load intermediate supports.
carrying members are aligned (See
Figure 9.1). Non-Load Bearing Wall: Walls
which do not support any loads.
Jack Stud: A vertical structural
member that does not span the full Punch-out: A hole in the web of a
height of the wall and supports steel framing member allowing for
vertical loads and/or transfers lateral the installation of plumbing,
loads. Jack studs are used to electrical, and other trade
support headers (See Figure 9.1). installation.
79
Stud: Vertical structural element of a Web: The part of a C-section or
wall assembly that supports vertical track that connects the two flanges
loads and/or transfers lateral loads (See Figure 9.2)
(See Figure 9.1).
Web Stiffener: Additional material
Top Plate: A plate used to carry that is attached to the web to
truss loads from the roof to the strengthen the member against web
studs, where the studs are not crippling. Also called bearing
located directly under the truss load stiffener.
points. The top plate has a web and
flanges but no lips. Yield Strength: A characteristic of
the basic strength of the steel
Track: Used for applications such as material. It is the highest unit stress
top and bottom plate for walls and that the material can endure before
band joists for flooring systems. The permanent deformation occurs.
track has a web and flanges, but no
lips. Track web depth measurements
are taken to the inside of the flanges
(See Figure 9.2).
80
9.4 STEEL FRAMING DESIGN
81
In a steel framed house, the loading path of the house structure is used to
determine the design requirement (See Figure 9.3). The roof loads, wind loads,
wall loads and floor loads will be transferred all the way down to the ground floor.
The sizes and spacing of the structural members would depend on the design
loads. Generally, BHP Steel Lysaght recommends the following:
• Lysaght C75 and Lysaght C100 sections would be used as the wall studs.
• As for the floor joists, they can be chosen from a range of sections ranging
from Lysaght C100 to Lysaght C250 sections depending on design loads and
floor configuration.
Connections for steel framing can consist of self-drilling screws, bolts and
anchors. Welding is usually not required and mechanical fasteners would suffice
in most cases.
82
9.5 WALL SYSTEM
A load bearing wall is one which carries vertical loads from the construction
above or lateral loads resulting from the wind. These loads may act separately
or in combination. Both internal and external walls may be load bearing.
BHP Steel Lysaght recommends the following for the load bearing walls:
• All load bearing studs shall be minimum Lysaght C75 G550 cold formed
section.
• A structural top plate is used to carry truss loads from the roof to the studs,
where the studs are not located directly under the truss load points. Top
plates shall be Lysaght G550 cold formed section (Structural plate). The top
plate shall be secured transversely at a maximum of 1800mm centres by
incoming trusses or rafters with approved wall support brackets.
• The bottom plate shall be minimum G550 cold-formed section. The bottom
plate must be fully supported under every load-bearing stud. This is critical
with studs beside openings, or studs carrying major loads for the roof, ceiling
or upper floor construction. The support can be provided by a floor joist,
blocking piece or concrete slab located directly under the stud.
• Lintels are needed for openings greater than 1200mm of load bearing walls.
Lintels under sheet metal roofs are principally designed for uplift from wind
loading on the roof structure while lintels under tile roofs are designed
principally to support downward loads from the roof trusses.
• Noggings in the form of a notched plate may be used in load bearing walls to
provide lateral restraint to the wall studs.
• The studs, joists and trusses must be properly aligned in order to transfer the
loads to the member below.
Internal walls which do not support truss loads are considered non-load bearing.
BHP Steel Lysaght recommends the following for non-load bearing walls:
83
• Studs for internal non-load bearing walls shall be minimum Lysaght G550
C75 cold formed section.
• Top plate should be minimum G550 cold formed section and shall be fixed to
trusses at 1800 mm maximum centres to provide lateral stability for the wall.
The connection shall not transmit vertical loads to the wall.
• Angle lintels are not required for openings in non-load bearing wall frames.
Steel framing is fastened to the floor structure through the bottom plate after all
panels have been correctly aligned and plumbed. For concrete floor slabs the
frame is fixed in place by using masonry anchors, which are generally hammer-
driven nails, expanding shell anchors or chemical anchors. Exact
recommendations for the type and frequency of anchors would be available from
steel suppliers or the engineer. The wall panels are usually connected together
by mechanical fasteners such as self-drilling screws.
84
Figure 9.4 Load Bearing Wall Details & Installation
Bottom Plate
Nogging
85
Figure 9.6 Stud to Plate Connection
Details recommended by BHP Steel Lysaght
86
9.5d Wall Openings
Figure 9.9 Window sill details Figure 9.10 Window jamb details
87
9.5e Wall Cladding & Partitions
If required in the external walls, reflective foil sarking may be attached to the
external flange of the steel studs with self-drilling screws fitted with 25mm flat
fibre washers. Alternatively wafer head screws may be used. Wire brick ties
which simply clip on to steel studs are available for brick veneer construction.
For single wall construction, fibre cement sheeting can be fixed to steel frames
with self-drilling, self-embedding head screws. Timber weatherboards can be
fastened to steel studs with extended point countersunk head self-drilling
screws. Steel sheet cladding is also fixed with self-drilling screws.
Lattice Beam Flooring (see Figure 9.14) gives a stronger and stiffer base for the
floor-board to be fitted onto. This will eliminate squeaky sounds made when floor-
boards are not properly fastened onto the beams. It also gives better sound
insulation between the ground and upper floor. This flooring can be used on
platform support or where the ground is split-leveled.
88
Figure 9.12 Steel frame wall & flooring using C-sections
89
Figure 9.14 Lattice Beam Flooring
Details recommended by QWik Built-Tech International Pte Ltd
The following shows some suggested details of floor finishes on the floor board:
Figure 9.15 Floor finishes with timber Figure 9.16 Alternative floor finishes
flooring with granite flooring
90
9.7 ROOF SYSTEM
The roof structure is generally a steel truss system which can be designed for
metal sheets or tiles. This is a roof truss system which typically consists of C75
and C100 sections as the chord and web members of the truss. The steel roof
framing system can suit all types of roof design – hip, gable, dutch dable, steel
roof sheeting or tile and would be screwed directly onto the wall frame.
When using tiles, wooden-styled roof trusses are used with purlins running
across them for the tiles to be fitted.
Pre-punched service holes in the web of the steel frame allows electrical, gas
and plumbing services to be installed within the wall framing system. Plastic
grommets and silicone seals are used to fasten and protect wiring and pipes from
corrosion and damage arising from vibrations.
91
Pre-punched holes for services Services can be suspended from
steel frames
92
Chapter 10 CONSTRUCTION METHOD FOR LIGHT
GAUGE STEEL FRAME SYSTEM
93
The general procedure is as follows:
1) The wall layout is marked on the floor using straight lines.
2) Squareness is checked by accurately measuring diagonals in large areas of
the house first, then individual rooms.
3) Internal wall frames are stacked inside the boundaries and external walls
around the foundations, with the first frame on top.
4) External frames are placed around the perimeter with their bottom plates
adjacent to their final positions.
5) Starting at any convenient external corner stand and plumb a wall frame panel
in its exact position.
6) Stand and plumb the adjoining frame to make a self-supporting corner.
7) Clamp the frames together and check again that both frames are in their exact
locations and standing vertical.
8) Connect the frames using the manufacturers recommended method -
generally nails, screws or rivets.
9) Proceed with the erection of the frames around the house, standing internal
and external frames as they occur.
10) Provide adequate temporary bracing during wall frame erection. The line of
top plates in a run of walling should be checked with a string.
94
10.2 STEEL WALL FRAMING - Anchoring
Steel framing must be firmly anchored to the foundation or floor structure.
Wherever possible, the walls should be anchored as soon as possible after they
have been plumbed and aligned.
There are two forces you must account for when attaching walls to the foundation
or floor slab. These forces are shear and uplift. The Prescriptive Method for
residential cold-formed steel framing provides details, sizes and types of
anchoring.
Figure 10.4 shows the wall to foundation connection. J-bolts are commonly used
in such connections. A piece of stud is used as a washer when bolting the walls
to the foundation.
95
Figure 10.4: Wall to foundation connection
The load bearing walls of a steel-framed house must be braced to protect the
wall from shear forces and prevent the walls from racking. Shear bracing keeps a
house from leaning or falling over. There are two ways of applying shear wall
bracing on a steel-framed house; either structural sheathing or X-bracing.
Structural Sheathing
Zinc-coated metal sheet ie; 0.8mm thickness is adequate to keep the wall from
racking as long as there are not excessive openings in the wall or excessive
lateral loads.
In order for structural sheathing to be effective, it should be installed with the long
dimension parallel to the stud framing (vertical orientation).
• The metal sheet may be attached to the wall while panelizing or after the
wall is plumb and level.
• Make sure that the sheathing is fastened tightly to the steel frame.
• Draw the metal sheet up tight against the wall with No. 8 self-drilling
screws.
• Finish attaching the metal sheet with screws or pneumatic pins. (See
Figure 10.5 of the Prescriptive Method, Structural Sheathing Fastening
Pattern, shown here.)
96
Figure 10.5 Structural Sheathing Fastening Pattern
X-Bracing
It is recommended to either cut and tack the strap to the wall during panelization
or install the strap after the wall is in place. X-bracing can be installed after the
walls have been raised, plumbed, aligned and attached to the foundation or floor
deck.
The roof frame can be screwed directly onto the wall frame. Truss spacing can
be at 600mm centres for sheet and tile roofs or 1200mm centres for sheet roofs
only. The manufacturer's instructions on type, placement and number of fixings
should be followed at all times.
The same door and window frames used in timber-framed construction are also
used in steel-framed construction. If aluminium window frames are fitted into
timber they can be installed by fastening through the jamb studs into the back of
the reveal after positioning. If it is not possible to secret-fix the frame, as may be
the case with a window or door head, “countersunk head” self-drilling screws of
appropriate length can be driven through the frame and packing into the steel
framing. The same type of screws may also be used to fasten aluminium window
frames direct to steel frame openings.
97
10.5 INTERNAL DOOR FRAMES
Timber door frames in internal walls can be secret-fixed through the back of jamb
studs with screws or nails. Alternatively the frame may be fastened through the
jamb into the studs with “countersunk head” self-drilling screws.
If required in the external walls reflective foil sarking may be attached to the
external flange of the steel studs with self-drilling screws fitted with 25mm flat
fibre washers. Alternatively wafer head screws may be used. Wire brick ties
which simply clip on to steel studs are available for brick veneer construction.
For single wall construction fibre cement sheeting can be fixed to steel frames
with self-drilling, self-embedding head screws. Timber weatherboards can be
fastened to steel studs with extended point countersunk head self-drilling
screws. Steel sheet cladding is also fixed with self-drilling screws.
98
10.7 INTERNAL WALL LINING
99
Chapter 11 PREFABRICATED COMPONENTS
The installation of the household shelter (HS) is often in the critical path of construction
works and often affects the progress of concurrent works on site. Hence, the use of
precast household shelters in place of the current in-situ design will likely reduce the
construction period.
A precast HS system, comprising L-shaped wall panels, has been developed. This precast
system is more buildable and will be of better quality in comparison with those systems
currently available. At the same time, the production costs of these new precast HS
systems are comparable to those for in-situ shelters. This precast HS system will also
eliminate the need for propping works on site. These potential savings in time and costs
will make the precast shelters more attractive than conventional design.
• Attached diagrams show the proposed precast 'L' panel arrangement and the two
standardised basic shelter dimensions.
• The 'L' panels are stable during installation, subject to the base conditions.
• RC stumps are provided at the base of the panels to support the panel weight
before casting the shelter base slab.
• The 'L' panels reduce the amount of in-situ casting required for walls.
The weight of the 'L' panels is in the order of 5.5 to 6 tonnes. If this presents a problem to
the crane lifting capacity, a lighter flat panel weighing 4 tonnes can be adopted. Refer to
Figure 11.1, Figure 11.2, Figure 11.3 and Figure 11.4 for different views of the HS shelter.
For both proposals, the base slab and top slab are constructed in-situ.
Note:
100
Figure 11.1 Plan showing type 1 (2m x 1.7m) of Figure 11.2 Plan showing type 2 of precast
precast household shelter household shelter
Figure 11.3 Plan showing type 3 of precast Figure 11.4 Plan showing type 4 of precast
household shelter household shelter
101
Recommended joint details
QP to consult BCA on actual application
102
11.2 PRECAST BOUNDARY WALLS
Precast boundary walls are similar to precast wall panels but are typically of smaller sizes.
This makes them quite ideal for precasting as the smaller panels mean that the contractor
would have fewer problems with handling, transportation and installation on site. At the
same time, additional use of such precast components will result in improved site
productivity and construction quality.
Joint details
The considerations for proper joint details in the precast boundary panels are similar to
those for precast wall panels. The design of the wall joints will include the following
considerations:
• water tightness
• installation method
• structural movement
• type of wall finishes
• panel sizes
• weathering
• tolerance
Finishes
The use of precast boundary walls continues to allow a wide range of design flexibility
and innovation.
There is a wide range of surface finishes that the architect can use on the precast
boundary wall design. The most common techniques used are modeling techniques like
sand blasting, acid washing, polishing and honing, hammering and chipping to create the
required effects. These finishes can then be treated with appropriate protective coatings
to prevent weathering and staining problems.
A wide range of colours for precast boundary wall panel can be derived from aggregates,
cement or pigments. Aggregate can provide colour to the final finishes. Cement with
different colours can also give the desired colour for the boundary wall panel. Another
form of colour finishes are colour and oxide pigments.
103
Figure 11.6a Details of the precast concrete boundary wall (type 1)
104
Figure 11.6b Details of the precast boundary walls (type 2)
105
Figure 11.7 Installation of wall base Figure 11.8 Precast walls are placed
and propped
106
11.3 PRECAST METER CHAMBER
A precast meter chamber/ compartment can be used. The meter chamber is the
housing for the electrical meter, water meter, SCV/ TV board chamber and letterbox.
The chamber is also very often the pillar for supporting the entrance gate.
The precast meter chamber is fabricated in two separate components; one is the
chamber and the other consists of precast concrete shelves which slot into the precast
chamber to separate each of the different services.
The size of the chamber is typically 800 x 800 x 1800 high. This results in a meter
chamber that is of manageable size and weight. Hence, this precast component can
be transported and installed easily. Moreover, the neat and proper
compartmentalization will make it easier to run and install the services between the
mains, the chamber and the house.
The finishes to the chamber can be similar to those for precast panels/walls and come
in a variety of textures, colours and effects. Figure 11.14a to Figure 11.14c show the
details of meter chamber type 1 and Figure 11.15a to Figure 11.15c show the details
of meter chamber type 2.
107
810
75 650 85
94
94 94 94
810 750
94
822 94 50 625 75
108
810
94 94
94 94
810 750
70 210 400
810
109
810
400
810
400
100 100
100 610 100 375 100
1285
500 500
111
100
810 100
475
500
1285
112
1150
1285
1285
113
11.4 PREFABRICATED STAIRCASE
The precast staircases proposed here are of standard sizes with tread sizes between
225mm to 250mm and risers between 150mm to 175mm. On the other hand, steel
staircases can come in non-standard sizes to suit the architectural design.
Precast/ steel staircases can be fabricated to a range of various forms and shapes.
There are three basic staircases profiles:
• Curved
• Straight
• Spiral profile
In the case of the terrace and semi-detached houses, these staircases can be fabricated
in three ways:
• Type A for flight only
• Type B flight and top landing
• Type C flight and base landing
The erection of the staircase can either be on the critical path or non-critical path of the
construction sequence. In each case, prefabricated staircases will result in better
quality, accuracy and productivity. The prefabricated staircases can be installed quickly
and messy, cast-in-situ works can be eliminated.
There are two main methods for fixing and installing the prefabricated staircases. The
staircase can either be prefabricated together with the landing as a complete unit or it
can be prefabricated separately and installed on site. The prefabricated staircase
should be designed to ensure easily transportation and hoisting. However, in most
cases, the size and weight are usually within the manageable capacity of the cranes.
114
Figure 11.15 Steel plate forming treads and Figure 11.16 Steel stringer beams with steel
rises treads
Figure 11.17 Steel plates supported by Figure 11.18 Steel plates supported by tension
centre column rods
115
Figure 11.19 Steel plates supported on Figure 11.20 Steel plates supported on 2 steel
vertical steel channels beams
116
Figure 11.22 Details to staircase in Figure 11.23 Details to staircase to frame
Figure 11.20 connections
117
11.5 METAL ROOFING SYSTEM
Over the years, metal roofing system such as corrugated metal and patented steel
roof-deck materials have gain much popularity in landed housing from the common
conventional timber battens and interlocking roof tiles.
Corrugated metal may be insulated and surfaced with build-up covering. Metal plates
formed with interlocking ribs which increase strength and stiffness are manufactured in
many different styles. These decks are usually covered with a vapor seal, a rigid
insulating board, and a built-up roofing. They are installed either with ribs up or with
ribs down. With ribs up these results a smooth ceiling which maybe shop-painted with
a baked–on enamel. If the appearance is objectionable with ribs down, an acoustical
material maybe applied to the lower surface.
118
House at Sunrise Drive
Architects: LOOK Architects
Main Contractor: Good View Construction P L
Details recommended by BHP Steel Lysaght
119
120
House at no. 35 Jalan Rukam
Architects: CLLA Architects P L
Main Contractor: Jimac Pte Ltd
Details by recommended by BHP Steel Lysaght
121
122
House at no. 73 Thomson Ridge
Architects: AXO Architects International
123
124
Chapter 12 CASE STUDIES
The following projects A, B, C and D are on-going projects or projects that were
recently completed. These developments use prefabricated systems like precast
structural steel or a hybrid system using steel column and flat plate system and light
gauge steel frame. The projects have demonstrated a construction-efficient design
with better quality and improved site productivity.
The subsequent projects E, F and G are completed projects using conventional cast-
in-situ system. The project teams reviewed the possibilities of using a prefabricated
system in these projects. It was found that a change to a more buildable precast
system was possible with no major changes to the elevation or the interior layouts.
125
12.1 PROJECT A - 81 units 3-storey terrace dwelling houses and two
semi- detached houses
General Information
Background
The developer has opted for precast construction to achieve better quality,
consistency and better buildability. This project is sited along Ang Mo Kio Ave
1 with a site area of approximately 2.2 hectares. The land slopes 18 metres
from one end to the other.
Prefabrication solution
The precast system consists of both structural and architectural elements such
as party walls, facade walls, floors, staircases, meter compartment and planter
boxes. RC pour strips were used at the wall joints and slab joints. The RC
pour strips provide for a watertight connection and to minimize cracking at
these joints.
To further reduce labour intensive finishing work, the end walls were
constructed using facade brick tiles that were precast together with the RC
walls.
Issues Encountered
The main challenge to the engineers and architects was the hilly terrain and the
staggering site arrangement of the houses. Proper planning with precision in
detailing and construction was vital to overcome the physical constraints.
Facade design and interior spaces were slightly modified where necessary to
adapt the precast system. However, the overall design concept has not been
affected.
126
Project A
Figure 12.1 Erection of precast walls and Figure 12.2 Use of 50-tonne crane for
planks hoisting
127
12.2 PROJECT B - A 2-storey semi-detached dwelling house
General Information
Background
The building is a two storey semi-detached dwelling house with a roof terrace.
The designers have ensured a safe and economical structure that would fulfill
its intended usage.
Prefabrication solution
The secondary steel universal beams were spaced to support the composite
slab such that during casting no additional props were required. The main steel
beams supported the secondary beams and transfer loads to the columns. The
composite slab with its welded mesh formed horizontal ties and provided lateral
restraint to the beams.
The hollow section columns were in-filled with concrete to achieve the minimum
half-hour fire resistance.
Issues Encountered
128
Project B
129
12.3 PROJECT C - A 3-storey semi-detached dwelling house
General Information
Background
The building is a three storey semi-detached dwelling house with a metal pitch
roof along Upper Changi Road East.
A cost estimate study of the project indicated that if the technique was applied
on a larger scale, such as 5 houses onwards, the cost savings could be
significant. This was due to the high level of prefabrication and mass
manufacturing inherent in the process and, of course, to the faster speed of
construction. Faster M&E installation, faster architectural finishing work and
reduced unskilled labour requirements meant lower costs all round.
The lightweight steel structure also demonstrated that the house could be
adapted easily to accommodate ecological considerations such as recycling
rainwater, harnessing solar energy and reduced air-conditioning. A 2300 litres
tank allowed the owners to have a week supply of recycled rainwater for
washing, gardening and koi pond use.
By having a mildly reflective metal roof with large roof airspace gap, good
insulation and light cladding materials, it was found that the building retains
much less heat compared to conventional RC buildings which tend to retain
130
heat for a longer period. In fact the owners reported that they seldom turned on
the air-conditioners during the day.
Issues Encountered
Hence, a change in the mindset is necessary since this system has proven to
greatly improve the site productivity and is a more friendly construction method
to the neighbourhood.
131
Project C
Figure 12.9 External cladding to fibre Figure 12.10 A view from the garden
board walls
132
Figure 12.11 Construction of first storey. Only the front panel used CIS construction,
all other areas used light gauge steel frames
133
Figure 12.13 Construction of 3rd storey
General Information:
Background:
The typical 3-storey units consisting of 5 Bedrooms with Living, Dining, Kitchen
and Utility have been designed to conform to local standards. The household
shelter shown in the proposal is not part of the original plans. They have been
added to meet current building requirement for the purpose of this study. Other
elements remain unchanged as in the actual project.
In the new proposal, the overall layout has been maintained with some minor
adjustments due to the inclusion of the precast household shelter. The wet
areas have been kept at the same side of the plan and as much as possible the
toilets have been stacked one above the other. Shower areas and balconies
have been provided with 50mm high kerb instead of providing the structural
drop to the slabs. Party wall, front/rear wall, boundary wall, staircase & meter
box are precast units. In line with the BCA buildability guidelines, the floor to
floor heights have been kept repetitive (except 1st storey) in multiples of 175mm
(standard staircase riser height). The vertical joints formed at the junctions of
the party wall with the front wall panel have been suitably concealed with GRC
box-up.
135
Precast Findings:
1. The case study found that the party walls could be designed as precast
shear walls due to the following advantages:
a) For terrace houses, there are no disadvantages to the use of precast
shear wall.
b) In party walls, there is no necessity to cater for future openings, e.g.
doorways and duct penetrations.
c) Vertical pour-strips between each shear wall panel is necessary to
eliminate vertical joint lines.
d) Precast columns can be used at the localised staircase/void areas to
support the precast slabs.
Conclusion:
The findings of the case study revealed that the precast system can be adopted
with very minimum adjustments to the original layout plans.
136
137
138
139
12.5 Project E - In-fill Terrace Houses
General Information:
Background
This case study project is located within an existing housing estate. The brief
calls for total reconstruction to two units of intermediate terrace houses for two
separate clients. Both houses are 2 storeys with an attic floor and a pitched
clay tile roof above. Space requirements are generally quite typical to local
standards. Household shelters are not part of the original plans / building.
They are added to meet current building requirement for the purpose of this
study. Other elements remain unchanged as in the actual project.
As an in-fill project, existing party walls adjoining neighbours on both sides are
not disturbed, i.e., the new buildings are structurally independent of their
neighbours. New columns and beams are added next to the existing party walls
to support the new structures. Conventional construction consisting of cast-in
situ RC frames together with brick wall in-fill is used throughout the project.
Precast Findings
The pre-cast system consists of precast RC panel for the front and back walls,
pre-cast party wall panels, precast floor with an in-situ topping. Other pre-
castable items include staircase and planter boxes.
Issues Encountered
There is a concern with the ability to transport and hoist large pre-cast panels in
an existing housing estate. A solution is to break up the front façade into two
smaller panels at each floor for ease of transportation. Minor architectural
adjustments are needed. Vertical groove lines are deemed acceptable and can
be easily treated.
On plan, the new structural columns at party wall are replaced by precast
panels with slightly larger footprints. Minor adjustments to toilet layout are
needed to suit the structural elements.
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Conclusion
This design of the building is such that it is quite easy to precast. Only very
minor changes to original design is needed.
Project E
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142
12.6 PROJECT F - Semi-Detached Dwelling House
General Information
Background
Precast Findings
Issues Encountered
There is no problem with transporting and lifting the large pre-cast panels in the
existing site, as the panel walls have been broken up into smaller panels for
ease of transportation, hoisting as well as installation. The wall panel could be
treated with various finishes. The groove lines, which run vertically and
horizontally can be acceptable and it is easily treated.
Conclusion
There is not much problem in implementing a pre-cast system for the building
as only a minor change to the elevation of the building is expected.
143
144
Elevation showing conventional construction
145
Appendix
6000
1m HIGH PARAPET
I
BALCONY
BEDROOM 1
FAMILY
LIVING
MASTER BEDROOM
RC FLAT ROOF
CAR PORCH
- -r RC FLAT ROOF
146
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147
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148
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s stem
149
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system system
150
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Figure 13-11 2n storey plan - Flat plate with steel Figure 13-12 3' storey plan - Flat plate with
column steel column
151