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SMART REINFORCINGBETTER • FASTER • CHEAPER

foreword

MITA (P) 269/06/2003

Oct 2015

Investing in Productivity In the Built Environment Sector, it takes all stakeholders to drive productivity.

BCA has provided a good framework for all stakeholders to jump onto the productivity bandwagon, especially with the second Construction Productivity Roadmap where S$450 million has been set aside for the second tranche of the Construction Productivity and Capability Fund (CPCF) in the next three years to help the built environment sector make higher investments in impactful productive technologies and improve the quality of its workforce.

Besides Government funding and support, builders can adopt many productive design and technologies available to increase productivity on site. Prefabrication of reinforcement is one such technology that can improve site productivity and add value to the construction value chain.

In this issue of our newsletter, we showcase an industrial factory project where more 90% of the reinforcement are prefabricated to achieve time, labour and cost savings for the main contractor.

Also featured are various prefab solutions for public housing multi-storey carpark (MSCP). These solutions can help the contractor fast track the construction of MSCP and reap time and cost benefits and achieve huge productivity improvement.

BRC is the Diamond Sponsor (Productivity) for the Singapore Construction Productivity Week from 13 to 16 October 2105. Come visit us at Buildtech Asia 2015 Exhibition at the Singapore Expo Hall 3 Booth G17.

Together, we can help the Built Environment Sector build “Better, Faster, Cheaper”

Lim Siak MengGroup Managing Director

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• 1.0 MT cantilever beam for Multi-Storey Carpark.• Conventional tying took 3 workers 1 day to to complete or 33 manhour/MT.• 3 workers took 15 minutes to install the prefab beam or 0.75 manhour/MT.• Time savings of 98%. Huge impact in productivity and manpower savings.

Public Housing at Corporation Road - Mutli-storey Carpark Prefab Cantilever Beam

Original reinforcement detail.

1. Preparation for beam hoisting.

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Cost ComparisonConventional – say $8.00/manhour x 33 manhour = $264 per beamPrefab – say $8.00/manhour x 0.75 manhour + $150/MT prefab charge = $156 per beam.Savings of $108 per beam or $2592 per deck of 24 beams.

Public Housing at Corporation Road - Mutli-storey Carpark Prefab Cantilever Beam

2. Cantilever beam lowered into position through column starter bars.

3. Cantilever beam installed in 15 minutes.

98% Time Savings

NEW!

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Fonda

• Multi-storey carpark roof slab with planks and topping mesh.• Reinforcement – D13 mesh + additional T13-100 at various locations, D10 mesh. Additional bottom mesh D7, D8, D10.• To minimise lapping and maximise site mesh laying productivity, D13 mesh was converted to twin wire F-mesh (single-directional mesh), incorporating the additional T13-100 bars.• Each sheet of F-mesh is about 160kg which is easy for the steelfixer to handle compared to a sheet of 200kg to 300kg D13 mesh. Fast

erPublic Housing at Canberra Street - Mutli-storey Carpark Roof Slab

Original reinforcement detail.

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Fast

erPublic Housing at Canberra Street - Mutli-storey Carpark Roof Slab

1. Additional bottom mesh laid. Mesh reference of D7, D8 or D10 determined according to slab thickness.

2. Single-directional F-mesh.

Complete Prefab Solutions

for MSCP

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Che

aper

• Laying each sheet took about 2 minutes.• Significant time and labour savings from the incorporation of additional T13-100 bars into the mesh.

Public Housing at Canberra Street - Mutli-storey Carpark Roof Slab

3. Workers carrying a sheet of 160kg F-mesh. Laying each sheet took about 2 minutes.

4. Both vertical and horizontal direction of F-mesh completed.

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Che

aper • Reinforcing work per cast took 1.5 days.

• Original specifications of D13 mesh + T13-100 additional bars will take 3 days.• Time saving of 1.5 days.• 15% material savings from elimination of excessive lapping (F-mesh compared to D13 mesh) .

Public Housing at Canberra Street - Mutli-storey Carpark Roof Slab

5. An arial view of the mesh laying work in progress.

Saved 1.5 Days

6. Mesh completed, ready for inspection and casting.

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42 Storey Residential Building at Robinson Road

• Planter wall mesh for roof garden on top of the mutli-storey carpark.• Reinforcement specified as D8 mesh.• Anchorage detail changed to allow mesh to be inserted easily. Bet

ter

Public Housing at Canberra Street - Mutli-storey Carpark Roof Planter Wall Mesh

1. D8 planter wall mesh.

Original reinforcement detail.

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42 Storey Residential Building at Robinson Road

• 300m run of planter wall per cast reinforced with 6.7 MT of mesh.• Mesh installed by 6 workers in 1 day.Bet

ter

Public Housing at Canberra Street - Mutli-storey Carpark Roof Planter Wall Mesh

2. 500mm high wall installed.

3. 750mm high wall completed for casting.

Completed in 1 Day

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• Large span 16m long multi-storey carpark roof beam.• Reinforcement: T13-75 links with T32 top and bottom beam bars. • Total weight : 7.2 MT per beam.• Due to construction methodology and sequence, the beam can only be prefabricated with the links, bottom and side bars.Bet

ter

Public Housing at Canberra Street - Mutli-storey Carpark Roof Prefab Beam

Original beam reinforcement detail.

1. Prefab beam with only links and bottom bars in place.

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Fonda

• Each 3.8 MT prefab beam was installed in 10 minutes. The rest of the top and lapping bars were tied on site manually.• The existing method of tying beam cages and loose bars took 8 workers 4 days to complete 8 beams for each cast.• Using prefab beams saved 1.5 days per cast.Bet

ter

Public Housing at Canberra Street - Mutli-storey Carpark Roof Prefab Beam

Original beam reinforcement detail.

3. Installation of the prefab beam took only 10 minutes.

Saved 1.5 Days

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Che

aper

42 Storey Residential Building at Robinson Road6 Storey Industrial Factory at Senoko - Heavy Beam and Slab

• Conventional beam and slab structural system.• Large beam – 1000 (W) x 1200 (D), upto 27 x T32 top bars in 3 layers, 23 x T32 bottom bars in 3 layers + T16-75/150 stirrups.• Slab – T16-150 both ways, top and bottom.• Reinforcement for the first cast for 2nd storey was tied manually using loose bars.• The steel fixing work took 11 days to complete with 8 workers.• Total tonnage for beam and slab was 102 MT per cast.

2nd storey beam and slab layout.

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Che

aper

42 Storey Residential Building at Robinson Road6 Storey Industrial Factory at Senoko - Heavy Beam and Slab

• For the 2nd cast of similar area, the beams were partially prefabricated with stirups and bottom bars and the slab rebars were converted into single directional mesh. • Installation of the beams and fixing all the loose top and connecting bars as well as the stirrup capping took 3 days by 8 workers. • Total tonnage for beams was 65 MT.

2. Beams completed with top bars and stirrup capping.

1. Installing a 7.8 MT partially prefab beam took only 15 minutes.

Break Through in Total Prefab

Solutions

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Fast

er • Laying of the slab mesh by 8 workers took 1 day to complete.• Total tonnage for slab was 37 MT.

6 Storey Industrial Factory at Senoko - Heavy Beam and Slab

2nd storey slab details.

3. Slab bars converted to single directional mesh for express laying.

Over 90% of Reinforcement Prefabricated

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Fast

er • The steel fixing work for second cast using prefabricated beams and slab mesh took only 4 days to complete.• Saved 7 days per cast.

6 Storey Industrial Factory at Senoko - Heavy Beam and Slab

Saved 7 Days

4. Beams and bottom slab completed.

5. Laying final part of top mesh before casting.

“Using BRC’s prefabricated wall, column, beam reinforcement as well as slab mesh allow me to reduce the overall construction duration by 4 weeks and earlier completion of the project.” Mr Vincent Ong Managing Director Jinmac Pte Ltd

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BRC ASIA LIMITED

350 Jalan Boon LaySingapore 619530

Telephone enquiries 6265 2333 Fax 62664728

Visit our website at www.brc.com.sgOr email us at sales@brc.com.sg

Dormitory Blocks at Choa Chu Kang

• Fast track dormitory project.• Precast column, beam and plank system.• A7 topping mesh throughout for slab.• 2 workers took 6 hours to complete 4 bays using large sheets.• Patch work using small sheets of mesh will take at least 12 hours to complete.• Time savings of 50%.

A7 mesh layout.

B

C

D

1 2 3 4 5 6 7 8

T1- 1/6 T2- 1/6

S

LS S

T3- 1/6 T4- 1/6T5- 1/4 T5- 6/9

T5-5 T5- 10

S

S

SS S

S

LS S S

S

S

50% Time Savings

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Bet

ter

Condominium Development at Boon Lay Way - Progress Report

Structural works completed for one of the 17-storey blocks.

3 Months Ahead of Schedule

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Bet

ter Progress Report:

• Achieved cycle time of 8 to 9 days versus planned 12 to 14 days.• Structural completion is 3 months ahead of schedule.

Saved 1 Day Per Floor Slab Mesh

Precast Column and External Façade

Prefab Storey Shelter/Lift Wall

We featured this condominium project at Boon Lay Way in our November 2014 issue of our newsletter. Let’s take a look at the time and labour saving methods/material used :

Saved 2 Days Per Floor

Saved 2 Days Per Floor

Condominium Development at Boon Lay Way - Progress Report