PRE-CAST ONE

PRE-CAST CONCRETE SHEAR WALL DESIGN

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PRE-CAST CONCRETE SHEAR WALL DESIGN THE METHOD OF CONSTRUCTION,

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ALLOWS THE EFFICIENT PLACEMENT AND CONNECTION OF REINFORCEMENT IN THE CRITICAL WALL / FLOOR JOINT,
PROVIDES FOR MORE REINFORCEMENT IN THE WALL / FLOOR JOINT THAN CURRENT PRACTICE, IDEAL IN SEISMIC AREAS. SITE BASED CASTING OPERATIONS USING FIBRE REINFORCED PLASTIC CASTING BEDS OPENS THE MARKET TO A LARGE NUMBER OF SUBCONTRACTORS COMBINED WITH SLABS IT PROVIDES A 100% IBS SOLUTION.

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IT IS MORE COST EFFECTIVE THAN CONVENTIONAL CONSTRUCTION

THE COMMERCIALIZATION OF PRE-CAST CONCRETE SHEAR WALL DESIGN. MARKET 1 HOUSING, and, 2 BUILDINGS IN SEISMIC ZONES
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CONVENTIONAL CONSTRUCTION

FLOOR SLAB
PRE-CAST ONE WALLS

THEN

WALLS

THEN

FLOOR SLAB

MORE REINFORCEMENT IN THE WALL / FLOOR JOINT

PRE-CAST ONE

UPPER WALL TEMPORARILY SUPPORTED ON STEEL PLATES CAST INTO WALLS 5

WALLS TEMPORARILY SUPPORTED PRIOR TO POURINJG CONCRETE

PRE-CAST ONE

MALAYSIAN COMMERCIALIZATION PROCESS THE USE OF SLAB FLOOR PANELS IN LIEU OF CONVETIONAL FORMWORK FLOOR CONSTRUCTION
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QUALITY ASSURANCE

WATER LINES CHASED INTO WALL 1 Quality control for the pipe component, 2 Pre-cast wall can flex during lifting.

PRE-CAST ONE

WALL ERECTED IN 15 to 20 MIN. WALLS CHASED FOR WATER PIPES QUALITY ASSURANCE

2 no. bolts with leveling plates U bars

ERECTION PROCESS
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2 no. bolts with leveling plates to receive Upper walls

slab

ERECTION PROCESS
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Structural topping slab slab

ERECTION PROCESS
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IBS CURRENT JOINT TECHNOLOGY PIN & GROUT

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Starter bars, 2 no. per wall

Wall 3.6m long x 3.3m high x 125mm thick

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= 2,400 kg

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Floor slab

PIN & GROUT JOINT

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Upper wall being lowered onto floor slab

Circular tubes for starter bars

Floor slab

PIN & GROUT JOINT

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Upper wall in position Floor slab

PIN & GROUT JOINT

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Starter bars, 2 no. per wall, Tolerance 12mm between bar and concrete

PIN & GROUT JOINT

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IBS CURRENT JOINT FIXING STARTER BAR WELDED TO PLATE CAST INTO WALL

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Starter bars 2 no. per wall

Wall 3.6m long x 3.3m high x 125mm thick

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= 2,400 kg

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Floor slab poured

Pre-cast wall with Starter bars

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Upper wall with plates embedded in wall To be weld fixed to the starter bars.

Pre-cast wall with Starter bars

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Upper wall lowered onto floor slab Starter bars welded to plates embedded in walls

Pre-cast wall with Starter bars

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Plate embedded in wall

Starter bar welded to plate

Floor slab

SECTION THROUGH WALL

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MORTAR BED AT BASE OF WALL ,

Difficult quality control

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DIFFICULT TO ALIGN WALLS AND CONNECTIONS

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PLATES IN WALLS WELDED CONNECTION

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WATEREPROOFING
125mm

1 ERECT LOWER WALL 2 ERECT SLAB 3 ERECT UPPER WALL 4 STRUCTURAL TOPPING

UPPER WALL
15mm drop to the bottom of the wall
structural topping

slab

LOWER WALL

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125 mm

WATEREPROOFING

Pre-cast Concrete wall

Wall tiles

Mortar bed 150 mm

Elastomeric membrane
150 mm 50 mm

Floor tiles

Cementicous membrane
Concrete floor

WATERPROOF WET AREAS 29

WATERPOOF DETAILS by PRE-CAST ONE

CONCRETE TO BATHROOMS CAST IN-SITU

FLOOR WASTE

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SYSTEM DESCRIPTION

COST COMPARISON

3 Bedroom, 2 bathroom unit =

Walls Pre-cast Concrete Shear Wall Conventional construction Concrete frame, brick & render Savings on walls per unit

119 m2.
RM /m2 135.68 RM /m2 149.26 RM 4,303.00 5%

Based on BRC

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MODULE - planning Housing units Typical unit Storeys bedrooms Bathrooms Manufacture at rate of Erect at rate of Walls 1/2 slabs Wet area slabs (cast in-situ) Manufacturing crew Erection crew Crane (erection) Structural topping crew Crane for structure & finishes 200 no. 119 m2 no. 3 no. 2 no. 1 unit / day / crew 1 unit / day / crew no. 15 no. 3 no. 122 persons = 5 no. / bed 10 persons 1 no. 26 persons 1 no. 32

CAPITAL COST Based on a module of 200 units in 8 months = 1unit/day capital cost Casting beds, walls no. 26 slab no. 15 Storage racks Bearers for slab support. Supply BRC cut & tagged U bars cut, bent & tagged Formwork accessories Conduits, Metal door frames Metal window frames RM 950,000 RM 550,000 RM 190,000 RM 175,000 RM 7,500/ unit RM 5,500/ unit RM 2,000 RM 500 RM 750 RM 1,100 33

LABOR MANAGEMENT LABOR ONLY SUBCONTRACTORS TO MANUFACTURE

LABOR ONLY SUBCONTRACTORS TO ERECT

MANUFACTURE AND ERECTION OF PRE-CAST CONCFRETE ELEMENTS IS, BASED ON INCENTIVE PERFORMANCE, i.e.. A FIXED AMOUNT PER ELEMENT FOR TIME & QUALITY.

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BUILDING MARGIN 100% IBS i.e. WALLS AND FLOORS, WITH CONDUITS, DOOR AND WINDOW FRAMES BUILT INTO THE PRE-CAST ELEMENTS, THE RISK TO THE CONTRACTOR IS LIMITED HIGH REPITITON FURTHER REDUCES CONTRACTORS RISK. MORE PROFIT ALLOCATED TO THE LABOR ONLY SUBCONTRACTORS PROVIDES INCENTIVE FOR THE EXPANSION OF A SKILLED LABOR FORCE IN DEVELOPING COUNTRIES AND THE DEVLOPMENT OF SMES.

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PROGRAM TYPICAL FLOOR HAND OVER 300 - 500 UNITS AT A TIME

PRE-LOAD FLOOR FLOAT STRUC TOPPING

EDGE BOARDS
REBAR TO STRUC. TOPPING ERECT WALLS & SLABS DAYS 0 1 2 3 4 5 6
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CASTING BED Fibre reinforced plastic

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CASTING BED Fibre reinforced plastic

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CASTING BED Fibre reinforced plastic

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FORM BOXES FOR STACK CAST SITE OPERATION

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CONCRETE OPERATIONS TO PRE-CAST WALLS 41

LEVEL CONCRETE SURFACE

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OPERATIONS COMPLETE 43

FORMS BEING REMOVED

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CASTING OPERATIONS

PANELS CAST ON SITE, STORED ADJACENT TO BUILDING

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SITE CASTING ON MOBILE CASTING BEDS WALLS AND SLABS

QUALITY CONTROL SIMPLE VISUAL INSPECTION 46

SITE CASTING ON MOBILE CASTING BEDS

MOBILE CASTING BEDS HINGED, SLABS

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TRAINING, MANUFACTURING,. LOGISTICS CENTRE (TMLC), set up for Housing Projects in Developing Countries for, a) MANUFACTURE OF WALLS, b) MANUFACTURE OF SLABS c) VOCATIONAL TRAINING 48

CURRENT IBS - FACTORY PRODUCED COMPONENTS 1 COLUMNS 2 no. 2 BEAMS 1 no. 3 FORM & POUR COLUMN and BEAM JOINT 3 EXTRUDED WALL PANELS (15 no.) 4 CEMENT RENDER, (quality of render never to specification).

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