16 innofund ppt

ENTERPRISE INNOFUND (EIF)
INDUSTRY CLUSTER
REFERENCE NO :
CF0116D1005
APPLICANT :
Concrete Society of Malaysia
TITLE :
Bio-inspired Concrete Innovation for Affordable
Quality Home

Introduction
Project Leader : Prof Dr Lee Yee Loon
Amount Applied : RM 500,000.00
Project Durations : 18 months
Proposed location :
No 28 Jalan Kerawang U8/108, Perindustrian Tekno
Jelutong, Seksyen U8, 40150 Shah Alam, Selangor

Project Members
No Roles Name
1 Project Leader Lee Yee Loon
2 Lead Researcher Muhd Fadhil Bin Nuruddin
3 Lead Researcher Hamidah Bt Mohd Saman@hj. Mohamed
4 Lead Researcher Lim Eng Hock
5 Member Ahmad Ruslan Mohd. Ridzuan
6 Member Anizahyati Binti Alisibramulisi
7 Member Kartini Binti Haji Kamaruddin
8 Member Nasir Shafiq
9 Member Chai Teck Jung
10 Member Lee Hoong Pin
11 Member Rabitah Binti Handan

Objectives
1. To fabricate and install a unit of bioCrete
affordable quality home model.
2. To test and monitor the structural integrity
and self-healing characteristics.
3. To establish a system and a group of installer
of the bioCrete affordable quality home.

Deliverables
One (1) unit of model of bioCrete affordable
quality home for humanity.

6
Elaborate on:
- Problem Statement. [ Existing affordable system unable to provide a
total solution to the probles]
- Novelty. [ proven concrete technology to be enhanced with
biotechnology]
- Prototype/ Proof of Concept (POC) [ Slides and videos ]
Project Description 6 minutes

7
Elaborate on:
- Technology benchmarking [ We benchmark against the world leader in
affordable concrete home in Japan, USA and Europe
- Potential/ existing Intellectual Properties (IP) [ Prestressed concrete
elements bonded with high performance adhesive]
- Video/ Pictures/ Diagram (to be presented separately)
Project Description (cont.)
2 minutes

Project Description
Flood is the most frequent disaster occurred in Malaysia according to Emdat–Frequency of
Disaster Event in Malaysia for the period 1990-2014. Still fresh in Malaysian mind , Malaysia
has been hit by its worst flooding in 30 years, leaving at least eight people dead and forcing
an estimated 160,000 from their homes. Even until now Kelantan is still recovering from the
worst flood disaster where plenty of victims still homeless. All floods disaster give a big
impact to the society especially in recovering back to the normal life from the extensive
damages to the victim’s home and life.
Emdat-Frequency of Disaster Event in Malaysia for the period 1990-2014
The most frequent disaster that occurring in Malaysia is Flood (62.5%), followed by Storm (12.5%), Landslide and Wildfire consist of 8.3%
respectively. Interestingly, Earthquake covered about 2.1% of the total disaster recorded for the last 15 years.

Novelty
Concrete Society of Malaysia aims to help the
flood victims with Bio-inspired Concrete
Innovation for Affordable Quality Home. A home
where can mitigate flood, fast build for fast
recover from disaster, affordable yet strong
enough equip with self-healing components for
a crackless wall

11
Methodology
Elaborate on:
- Methods / Process / Technology [ Lightweight concrete bonded with
cementless adhesive ]
- Process Flow Chart/Diagram [ slides separately ]
- Ethical/ regulation approval (if Applicable) [ compliance with
established standards ]
4 minutes

12
Milestones
No Milestones Activities Deliverable Duration
(months)
Cost
(RM)
1.
2.
3.
4.
5.
6.
Total Cost
These are key
achievements.
Wordings
must be
concise e.g.
Fabrication of
/ simulation of
/ Field trial
etc.
Activities to
support the
milestone
achievement.
Use verbs.
E.g. To design
/ To conduct/
To assemble
etc.
Deliverables to each
activity. Use past tense.
E.g. Sub-module
assembled / simulation
report submitted / Test
report / IP filed etc.
1 minutes

Milestone
No Milestones Activities Deliverable Duration
(months)
Cost
(RM)
1. Preparation of
materials & bio-
precast
components
- To procure materials
- To mix proportioning
& trial mixers
- To fabricate bio-
precast components
- All materials ready
- The materials
mixed
- The bio-precast
components ready
4 months 150,000
2. Testing the bio-
precast
components
- To perform structural
behavior test
- To perform fire
resistant test
- To perform self-
healing
characteristics
- Pass the structural
behavior test
- Past the fire
resistant test
- Pass the self-
healing
characteristics test
6 months 90,000
3. Installation of the
model house
To install the
components to
construct the model
house
The model house
ready for monitoring
2 months 144,500

4. Monitoring on-
site
- To perform
waterproofing test
- To perform structural
integrity test
- To perform self-
healing
- Pass the
waterproofing test
- Pass the structural
integrity test
- Pass the self-
healing
4 months 100,000
5. Submission of
final report
- To prepare &
register the IP
- To submit the
completed final
report
- The IP prepared
and regsitered
- The final and
completed report
submitted to
MOSTI
3 months 15,500
Total Cost 500,000
Milestone (cont.)

15
Project Costing
Component Amount
requested
(RM)
Your
contribution
(RM)
Total cost
for each
component
(RM)
A Pilot Plant/ Prototype
i……..
ii……..
B Pre Clinical/ Clinical / Field Trial
C Commercial Ready Prototype IP Preparation & Registration
D Market Testing/ Market Assessment
E Regulatory & Standard Compliance
F Expenditure of Services
G Contract Expenditure
H Consumables
I Technology Acquisition (if Applicable)
TOTAL (RM)
The amount that
you should put here
should be the sub-
total for each
component. The
Panel will refer to
your submitted
form that should
contain a more
detailed funding
requirements.
1 minutes

Project Costing
No Types of Costing Component Estimated Cost (RM) Amount Applied (RM) Total(RM)
A Equipment 44,500.00
Disposable materials • Glove, Safety shoe, Etc 5,000.00 5,000.00
Non-disposable materials • Tools, Safety Helmet, Container,
Hardware, Etc
39,500.00 39,500.00
B IP Preparation and Registration(Excluding maintenance) 15,500.00
Intellectual Property 15,500.00 15,500.00
D Regulatory and Standards Compliance 90,000.00
CIDB Certification 20,000.00 20,000.00
SIRIM Certification 70,000.00 70,000.00

E Expenditure for Services (Cannot exceed 20% of total project cost) 200,000.00
Perundingan/ Consultancy • Fabrication and Installation of a
unit model house
100,000.00 100,000.00
Pengawasan di tapak / Monitoring On-Site • Structure
Integrity (deflection and movement) • Waterproofing/
Permeability • Self-Healing Characteristic
100,000.00 100,000.00
F Raw Materials 150,000.00
Cement, aggregate, biomass silica ash and steel 100,000.00 100,000.00
Admixtures, chemicals and Bacteria 50,000.00 50,000.00
TOTAL(RM) 500,000.00
Project Costing (cont.)

18
Elaborate on:
- Market Potential [ RM 500 million per year]
- Price Competitiveness / Industry Competitor/ Entry Barrier – RM1
cheaper per ft2
- Return on Investment – 3 years
- Marketing Strategy, Distribution Network, Strategic Alliance
[ Chin Hin Group of companies ]
Commercial Potential 2 minutes

19
Elaborate on:
- Market Potential [ What are the demand, size, growth, target, niche,
penetration rate etc. ]
- Price Competitiveness / Industry Competitor/ Entry Barrier
- Return on Investment
- Marketing Strategy [ Who are your partners, contract manufacturer,
marketing arm etc. ]
- Distribution Network
- Strategic Alliance
Commercial Potential 2 minutes

1
2
3
4
5
6
7
PRESENTATION
OUTLINE

Concrete: The Basic Mix
Liquid part:
Solid part:

Creating better performance of concrete
with longer service life
Cement
Gravel
Silica Fume
Superplasticiser
Sand Retarder
Water Air
entrainer
Accelerator
GGBS
Steel Fibre
Recycled
aggregate
Fly ash

Concrete: Better performance and
longer service life
According to:
Schlangen, 2012

Self-Healing ambitions
According to:
Schlangen, 2012

Cost of repair vs healing
Cost
-
Performance
Time
Required strength
1st
repair 2nd
repair
A Normal
B High quality material
B High quality
A Normal
Cost
-
Performance
Time
Required strength
Self repair
Self Healing Material
According to:
Schlangen, 2012

• Bioconcrete is a type of concrete that adopts
biomineralisation induced by bacteria whether
to heal crack or to enhance concrete
properties. Biomineralisation results
precipitation of calcium carbonate (CaCO3)
(calcite) results from metabolic activities of
some specific bacteria in concrete.
• Bioconcrete is bacteria based self-healing
concrete (jonkers, 2007).

What is Bioconcrete? (cont’d)
• A new generation of concrete in which introduces
microbiologically-induced CaCO3 precipitation for
remediation of micro cracks (Arunachalam et al., 2010)
• A new generation of concrete in which selective
cementation by microbiologically-induced CaCO3
precipitation has been introduced for remediation of
micro cracks (Arunachalam et al., 2010).
• Bioconcrete is modelled on organisms that induce
microbial carbonate precipitation (MCP) through their
metabolic processes and in the presence of calcium
precipitate calcium carbonate (CaCO3) (Gonsalves, 2011).

BIOCONCRETE
• It’s a special type of
concrete invented by a
group of microbiology
researchers under the head
of Henk Jonkers.
• Bioconcrete also referred as
bacterial concrete or self-
healing concrete.
• Specially formulated to
increase concrete durability
and its lifespan by
continuous healing action.

Why
Bioconcrete?
1 SUSTAINABILITY OF CONCRETE
2 MINIMIZATION OF THE ENVIRONMENT
IMPACTS
3
ALTERNATE SUBSTITUTE TO
CONVENTIONAL CONCRETE
SMART BIO MATERIAL
4
NEW WAY OF DESIGNING DURABLE
CONCRETE STRUCTURES
5

• The bacterial species produce urease, which
catalyzes urea to produce CO2 and ammonia,
resulting in an increase of pH in the surroundings
where ions Ca2+ and CO3 precipitates as CaCO3.
• As a microbial sealant, CaCO3 exhibited its
positive potential to selectively consolidate
simulated fractures and surfaces fissures in
granites and sand plugging. The type of bacterial
culture and medium composition had a profound
impact on CaCO3 crystal morphology.

Biomineralisation
• Precipitation process of
mineral materials influenced
by living forms (Skinner and
Jahren, 2003).
• A process that utilise the
biochemical process of
bacteria (Lowenstan and
Weiner, 1988).
• Two (2) different conditions
1. Biologically controlled
2. Induced

• BCM defined as
mediated
mineralization of
organic-matrix
performed by many
animals, the
nucleation, growth,
morphology and final
location of deposited
mineral are based on
the cellular activities of
organisms.
According to: Weiner
and Dove, 2003
BIOLOGICAL CONTROLLED
MINERALIZATION (bcm)

BIOLOGICALLY INDUCED
MINERALIZATION (BIM)
• BIM referred to a metabolic
activity of the organism
subsidized with chemical
reactions that involved metabolic
by-products that will formed
nucleated and extracellularly
grown mineral.
• This type of biomineralization,
strongly depending on the
metabolism of the microorganism
for the secretion of biominerals.
According to: Weiner
and Dove, 2003

Biomineralisation
• Biomineralisation produce
calcium carbonate/calcite
(CaCO3) by common
metabolic activities.
• Photosynthesis
• Sulphate reduction
• Urea hydrolysis

Biomineralisation (cont’d)
• In self-healing concrete, the
mechanism of mineralization was
based on the understanding of the
resulted metabolic byproduct
mainly due to the nutrient supply
under favourable condition so that
the organisms able to create local
micro-environment that allow
precipitation of mineral phases
such as CaCO3 as define by
Biomineralization Induce
Mineralization (BIM).

Microbially Induced Calcite
Precipitation (MICP)
 The technique utilises biomineralisation process by
bacteria in diverse fields to improve its engineering
properties (i.e. strength, impermeability).
 The applications of this technique have shown promising
achievement in improvement of concrete strength and
durability (Achal et al., 2012; De Muynck et al., 2008), brick
durability (Sarda et al., 2009), soil (or sand) strength
(Gurbu et al., 2011; Lu et al., 2010; Ruyt and Zon, 2009;
Nemati and Voordouw, 2003) and sand impermeability
(Nemati et al., 2005; Nemati et al., 2003).

Steps involved in MICP
Flowchart
summarising steps
involved in MICP for
ureolytic bacterium
from the genus
Bacillus
According to:
Wong, (2015)

Self-healing mechanisms of
MICP on crack
According to:
Jonkers, (2007)

Criteria of Bacteria
Easily obtainable
Safe (not a pathogen)
Calcite-forming bacteria
Spore-forming bacteria
(resistant to pH and
temperature)

Species of Bacteria that produce
precipitation
Bacillus subtilis
Bacillus pasteurii
Bacillus sphaericus
Thermus thermophiles
Shewanella
Geobacillus stearothermophilus
Thermus aquaticus
Thermophilic

pH
Types of
bacteria
Nutrients
Bacteria cell
concentration
Reactant
concentration
Geometric
compatibility of
bacteria Bacterial
precipitation
Factors affecting the performance
of bacterial precipitation

VISUAL ASPECT OF BACTERIA
TO BE USED IN CONCRETE
• Bacteria efficiency in
different medium
(nutrient)
concentrations
• Bacterial ability to
continuously produce
calcite
• Bacterial survival
duration in specimens

Name
Composition
Microbial
cells conc.
(cfu/ml)
pH Temperature References
Nutrients Concentration
Growth
medium
1. Yeast extract
2. Urea
3. Calcium lactate
33.3 g/l
33.3 g/l
20 g/l
1x103 – 1x109
7.0-
9.0 60ºC
Mohd Azam et
al., (2015)
YU
medium
1. Yeast extract
2. Urea
20 g/l
20 g/l
109 7.0-
9.1
28ºC
Wang et al.,
(2014)
Nutrient composition for
the bacterial growth

Nutrient composition for
the bacterial growth (cont’d)
Name
Composition Microbial
cells conc.
(cfu/ml)
pH Temperature References
Nutrients Concentration
Precipitation
agar
1. Urea
2. NH4Cl
3. NaHCO3
4. CaCl2.2H2O
5. Nutrient
broth
20 g/l
2.12 g/l
10 g/l
25 g/l
3 g/l
103
105
107
- 28°C
Chahal et al.,
(2012)
Growth
medium
1. Yeast
extract
2. Urea
20 g/l
20 g/l
109 7.0-
9.1
28°C
Wang et al.,
(2012)
Medium
composition
1. Peptone
2. NaCl
3. Yeast
extract
5 g/lt
5 g/lt
3 g/lt
105 - 37°C
Sunil Pratap
Reddy et al.,
(2010)

Year Author Microorganism Findings
2015 da Silva et al.,
Non-axenic ureolytic
spores
 Production of Cyclic Enriched Ureolytic
Powder (CERUP)
 The incorporation of CERUP in concrete at
3% and 5% of the cement weight
decreased the compressive strength
 Lower incorporation of CERUP at 0.5%
and 1% did not substantially affect the
strength.
 The CERUP increased the autogenous
healing for cracks up to 0.45 mm after 4
weeks.
2015 Mohd Azam et al.,
Geobacillus
stearothermophilus
 Production of alginate-encapsulated
Geobacillus stearothermophilus (AEGS)
 Higher incorporation of AEGS (15%) by
mass into mortar decreased the
compressive strength as compared to
lower incorporation (3%).
 Higher healing efficiency on higher
replacement of AEGS into mortar at 80%-
100% at 60 days.
FINDINGS

Year Author Microorganism Findings
2014 Wang et al., Bacillus sphaericus
 Calcite precipitation
 Healing ratio of concrete with bacteria
was at (48%-80%) than in those
without bacteria (18%-50%).
 The overall water permeability was 10
times lower as compared with non-
bacteria series.
2011 Achal et al., Bacillus sphaericus
 Calcite precipitation
 Positive effect on compressive strength
and a decrease in water penetration as
compared to normal concrete (control)
2011 Chahal et al., Sporocarcina pasteurii
 Increasing the compressive strength of
fly ash concrete by 22% at 28 days
 Four (4) times reduction in water
absorption
 Deposition of bacterial calcite causing
nearly eight time reduction in chloride
permeability
FINDINGS (CONT’D)

MICROENCAPSULATED MATERIALS
– SELF HEALING MATRIX

Concept of binding effect in
self-healing concrete
According to:
Wong, (2015)

Encapsulation method
• Alginate-encapsulated
Geobacillus
Incorporation of Geobacillus
Stearothermophilus
Nutrient loaded into sodium
alginate broth
Hot plate stirrer for
cross linking process
Alginate-encapsulated
hardening process
Rinsed alginate-encapsulated
Geobacillus stearothermophilus

Scanning Electron Microscopy (SEM)
on Geobacillus Stearothermophilus
• Types: Gram-positive, Gram-
negative
• Shape: Rod
• Sizes: 2.0 – 3.5 µm
• Arrangement: Occurring singly
or in short chains
• Growth Temperature: Minimum
: 30 to 45 ºC Maximum : 60 to 70
ºC Optimum : 40 to 60 ºC
• Capable to produce endospore
under harsh condition
According to:
Mohd Azam et al., 2015

Scanning Electron Microscopy (SEM)
on encapsulation
Sodium alginate
gel
Geobacillus
Stearothermophilus +
nutrient
• Alginate-encapsulated Geobacillus Stearothermophilus (Mohd
Azam et al., 2015)

Scanning Electron Microscopy
(SEM) on encapsulation
Broken alginate-
encapsulated
Geobacillus
Stearothermophilus in
mortar
Binding effect by
bacteria
biomineralization
• Alginate-encapsulated Geobacillus Stearothermophilus (Mohd
Azam et al., 2015)

0 days 7 days
28 days 60 days
According to:
Mohd Azam et al.,
(2015)
• Encapsulation method – Sodium Alginate gel
• Bacteria - Geobacillus stearothermophilus

• Encapsulation method –
Cyclic Enriched Ureolytic Powder (CERUP)
• Bacteria – Non-axenic bacterial culture
According to:
da Silva et al., (2015)

According to:
Wang et al., 2014
• Encapsulation method – Hydrogels
Microencapsulated spores
• Bacillus sphaericus

• Voids filling
mechanisms
• Encapsulation
method – Bio
based agent
• Bacteria – Bacillus
cohnii
According to:
Sierra-Beltran et
al., 2014

According to:
Wang et al., (2011)
• Encapsulation method – Diatomaceous Earth (DE)
• Bacteria – Bacillus sphaericus

• Encapsulation method – Expanded clay particles
• Bacteria - Bacillus cohnii, Bacillus halodurans and
Bacillus pseudofirmus
According to: Jonkers and
Schlangen, 2007, 2008

• Method – curing in 50 mM calcium chloride solution with 1.5 × 108 cfu/ml
• Bacteria - Synechococcus PCC8806 strain
According to:
Zhu et al., 2015

• Scanning electron
micrographs of
CaCO3 crystals on
the surface of mortar
specimens treated
with Bacillus
sphaericus.
According to:
De Muynck et al., 2008

• SEM images of top surface of lightweight concrete treated by
the medium with Bacillus pasteurii measured in 100 μm (a),
10 μm (b), and EDS spectra at point 1 (c) and at point 2 (d).
According to:
Kim et al., 2013

• SEM images of top surface of lightweight concrete treated by the medium
with Bacillus sphaericus measured in 50 μm (a), 2 μm (b), and EDS spectra at
point 1 (c).
According to:
Kim et al., 2013

Bacillus licheniformis Bacillus megaterium
• Healing by Bacillus licheniformis and Bacillus megaterium after 81 days
by direct incorporation
According to:
Krishnapriya et al., 2015

Economy analysis of MICP concrete
• Cost of MICP largely dependent on the price of
nutrients and cost of bacterial strain
• The price of bacteria varies from country to country.
• Standard bacterial strain (Achal, 2015)
• However, bacterial strain can be used for many years by
sub-culturing at regular time interval.
Bacteria source Price (RM)
American Type Culture Collection (ATCC) 2000 and above
Microbial Type Culture Collection and Gene Bank
(MTCC)
40 and above
China General Microbiological Culture
Collection Center (CGMCC)
800 and above

 Detailed report on the cost analysis of MICP concrete (De Muynck et
al., 2010)
 Cost involved,
 For every 0.04-0.08 kg/m2,
 The nutrients cost can be reduced significantly by replacing
standard or commercially available nutrients with industrial
byproducts; rich in carbohydrate, protein and energy sources.
Bacteria Nutrients
Lyophilized bacteria
RM6400.00/kg
RM1100/kg
Nutrients Total product cost
(RM30.00 –
RM65.00)/m2
(RM133.00 -
RM177.00)/m2
ECONOMY ANALYSIS OF MICP
CONCRETE (CONT’D)

Several issues still need to be addressed on MICP (Pacheco-Torgal and Labrincha, 2013),
– Which calcite producing bacteria are more efficient in highly alkaline
environment?
– Can air-entraining agents be effective in preventing bacteria loss
associated due to reduction in pore size?
– Which is the most eco-efficient encapsulation method?
– Will biologically deposited calcite endure the test of time?
– Can biomineralisation be made cost-efficient?
– Are there any health implications involved in the use of bacteria?
– What is the life cycle analysis of biotech concrete?
ISSUES

Conclusions
 Suitable bacteria capable to heal cracks
in concrete by given proper
medium/nutrient to induce
biomineralisation.
 Immense opportunities in improving
technology
– Structural performance
– Economy
– Environmental
sustainability
 It needs input from different disciplines
– Create collaboration
between microbiologist
and civil engineers

Research conducted at
Universiti teknologi mara
(UiTM) on bacteria concrete

SEM IMAGE ON BACTERIA CONCRETE
SEM Micrograph of Concrete
without Bacteria
SEM Micrograph of Concrete with
Thermus Thermophilus

COMPRESSIVE STRENGTH OF CONCRETE
WITH BACILLUS SUBTILIS
According to:
Muhammad
Isha et al.,
(2013)

SEM IMAGE OF CALCITE TAKEN
FROM CRACK FILLING MATERIAL

81
Cost Indices and Technology Choice: Strategies for Industry Development
Dr.Toong Khuan Chan
March 2014

82
CONTENTS
• Background: International Cost Comparisons
– Davis Langdon Blue Book
– World Bank ICP for Construction
– The Economist Big Mac Index
• Cost Indices
– Indexed on Labour (Skilled Workers: hourly wages)
– Indexed on Concrete (30MPa, 1 cu.m, supply only)
– Indexed on Reinforcements (1 tonne, supply only)
• Case Studies
– Cast-in-place reinforced concrete vs. Precast concrete
– Concrete vs. Structural Steel
• Policy Drivers

83
INTERNATIONAL COST COMPARISONS

84
INTERNATIONAL COST COMPARISONS
• Construction costs
in US$ for various
capital cities
• Source:
International
Building Cost
Comparison, The
Blue Book 2011,
Davis Langdon

INTERNATIONAL ECONOMICS –
THEORY OF PURCHASING POWER
PARITY

87
GDP PER CAPITA (PPP ADJUSTED)
WORLD BANK 2011
. .

88
SUPPLY RATE OF 1 CUBIC
METRE OF CONCRETE IN US$
. .

89
HOURLY WAGE FOR
SKILLED WORKERS IN
US$
. .

OBSERVATION 1
• The Big Mac Index can provide a simple comparator for price differences across
countries
• Similarly, a ‘concrete’ index can provide a simple measure of cost relativities in
various locations
• Concrete (and therefore construction) is produced using local labour,
locally developed or traditional technologies, and
local materials to construct
buildings locally
• US$ does not really make sense for comparisons; prefer local currencies
90

BASIC INPUTS
Singapore US Australia Malaysia India
1 hr skilled worker S$ 22 US$ 66 AU$ 60 RM 18 INR 48
1 m3 concrete S$ 152 US$ 135 AU$ 186 RM 230 INR 5000
1 ton steel S$ 1770 US$ 992 AU$ 1250 RM 3220 INR 40,500

BASIC MATERIALS INDEXED ON
LABOUR
1 m3 concrete
1 ton steel

CONCRETE IN SLAB AND STEEL IN
BEAMS INDEXED ON LABOUR
1 m3 concrete in
slab
1 ton steel in
beam
1167!
1 sq.m formwork
to soffit of slab

CONCRETE IN SLAB AND STEEL IN
BEAMS INDEXED ON CONCRETE
1 m3 concrete in
slab
1 ton steel in
beam
1 sq.m formwork
to soffit of slab
0.2 0.5 0.7 0.2 0.1

95
CONCRETE, FORMWORK
AND PRECAST WALL
. .

OBSERVATION 2
• High income countries
– concrete is cheap relative to labour (<5 hrs labour)
– Singapore and UAE have large migrant workforce: low labour costs
– reinforcement is cheap relative to labour (8-30 hrs of labour)
• Upper middle income countries
– concrete is between 10-20 hours of labour
– reinforcement is between 50-200 hours of labour
• Lower middle income countries
– labour is cheap relative to concrete/reinforcements
– concrete is > 20 hours of labour (China:21, India:104)
– reinforcement is >200 hours of labour (China:218, India:844)
96

INTER COUNTRY COMPARISON OF RC
BUILDING
Reinforced Concrete Building Total Material Labour Plant
AU Rates 309 154 137 17
from Rawlinson (2010) 50% 45% 5%
UK Rates 110 47 50 14
from BCIS (2012) 43% 46% 12%
MY Rates 146 105 32 9
from Yong (2010) 72% 22% 6%
US Rates 141 63 76 -
from RSMeans (2012) 45% 54% 0%

COMPARISON OF CAST INSITU
VS PRECAST
Total Material Labour Plant
Australia (in AUD)
Cast-in-place Reinforced Concrete 309 154 138 17
50% 44% 6%
Precast planks, beams and columns 336 207 85 44
62% 25% 13%
Malaysia (in MYR)
Cast-in-place Reinforced Concrete 146 105 32 9
72% 22% 6%
Precast planks, beams and columns 384 336 21 26
88% 5% 7%

OBSERVATION 3
Australia:
• precast system is 9% higher - material ↑, onsite labour ↓, plant ↑ ↑
• high labour component in CIP indicative of the high cost of labour to erect scaffolding and
formwork, stringent OHS requirements
Malaysia:
• precast system overall cost that was 163% higher
• material cost for precast was 3X cast-in-place
• obvious advantages with pre-casting negated

100
STEEL VS CONCRETE
. .
Expensive steel structures
Cheaper steel structures

OBSERVATION 4
• Structural steel
– 10 to 25 times more expensive (1 tonne steel vs 1 cu.m concrete)
– steel is relatively cheap in US, Canada, Japan and India (17, 17, 8, 13 times)
– large steel production capacity
– more buildings built out of steel
• Reinforcing steel
– 7 to 15 times more expensive than concrete
– countries with higher steel use in construction have small gap between reinforcing steel
and structural steel
101

CONCLUSIONS
• Cost indices
– indices for basic materials are able to explain choice of technology
– high labour costs encourages the use of technology, and mechanisation
– migrant labour encourages the use of traditional methods of construction, labour intensive (eg
Singapore and UAE)
– predominance of steel structures over concrete in countries with large steel output
• Policy drivers for Industry Development
– labour vs technology: achieve gains in labour productivity first before capital productivity, provide
jobs and employment,
– prefabrication vs cast-in-situ: cast-in-situ is cheaper in low labour cost locations
– steel vs concrete: tradition, local manufacture of steel
– skilled vs unskilled: if wages are high, invest in technology instead; if wages are low, invest in training
to improve skills
102

103
CONTENTS
• International Cost Comparisons
AECOM-2013-Asia Construction Outlook 2013

104
CONTENTS
• International Cost Comparisons

QUESTIONS?
More information, cost data and analysis:
Dr Toong-Khuan Chan
Senior Lecturer | Assistant Dean – International
Faculty of Architecture Building and Planning
The University of Melbourne
Parkville, VIC 3010
AUSTRALIA
Email: tchan@unimelb.edu.au
105

106
Industrial – Tilt Slab
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107
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108
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109
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110
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112
Industrial – Tilt-up Construction

Biomass Silica
Grey Diamond and Green Power
Chemann Technologies Sdn. Bhd.
(Chemann JV RECESS)
Biomass Silica Cogeneration Process
(adapted from the approved TF0106D066)

• BioGen (Malaysia) Sdn. Bhd. is to be incorporated in Malaysia as a private
limited company under the Companies Act, 1965. It is a technology venture
launched by PP JV RECESS.
• BioGen’s initial paid up capital is RM 200,000.00. The principal activities of
the company is innovative exploitation of various IPs owned by universities
and inventors. Biomass silica is one of them.
• Its mission is to commercialise the IPs owned by CIDB and UTHM within 6
months.
• The commercialisation strategy includes:
i) business entity,
ii) source of biomass,
iii) strategic partnership
• PP Sdn. Bhd. is a wholly owned business arm of KBI and HV Group. PP is
expected to own 20 % of BioGen
• CIDB and UTHM are actively seeking various options of sources
• A maximum allocation of 20% for the intended source from Perak
Company Profile

• Technical
– Comprises expertise in Electrical and Civil
Engineering
– Supported by proven technologies from Belgium
and Finland.
• Management
– Innovation management by BioGen
– Financial and operational management by PP
Strength of Project Team Members

• This project is intended to commercialise two award winning
and patented (MY-140472-A & MY-139642-A) technologies
owned by CIDB and UTHM. The first patent is for the
production of biomass silica. The biomass silica is derived
from controlled incineration of agricultural wastes such as
rubber-wood bark, rice husk and oil palm kernel.
• Biomass silica is suitable for the production of the patented
cementitious IBS products. Another patent-pending
(PI20062030) technology is ready for deployment to provide
real-time remote monitoring and alert system for quality
assurance of power generation and biomass silica production
process. There is a sustained demand for biomass silica for a
variety of blended cement products, industrial coatings and
pastes.
Proposed Project

• The biomass power plant will be closely monitored
with the remote monitoring and alert system to
ensure its compliance to the environmental
requirements imposed by the authorities. Successful
implementation of this project is expected to
promote sustainable system of renewable energy
and sustainable development while promoting more
postgraduate studies towards enhancing capacity
building.
• While improving the quality of life of the rural
community in Perak this venture is aimed at
promoting green technology to the State.
Proposed Project (Con’t)

• RM6 million is required for the procurement and
kick-start the 500 kW gasifier micro turbine system
and BioGen plant.
Investment

• Synthesis of Amorphous Biomass Silica Patented
process (MY-140472-A) has led to the development
of several value added products related to
construction and industrial applications (MY-139642-
A).
• Remote monitoring and alert system has been
deployed for effective and safe operation of the
Biomass Silica Synthesis process.
Patent-pending (PI20063060)
Background of R&D

• Controlled incineration process to produce
Amorphous Biomass Silica.
(Patent document and journal articles may be
requested from Prof. Ir. Dr. Zuhairi bin Abd Hamid,
Executive Director of CREAM, CIDB. Support for
funding and approval needs advice from Tan Sri
Jamilus, the Chairman of CIDB)
Core Technology

• Three value-added products, i.e. electricity
and heat, biomass silica and the remote
monitoring and alert system.
• There is a good demand for the products.
(RM100 million/year, Ref. CRDF 1 market
survey report)
• Possibility of selling to TNB at reasonable rate
(at least RM0.20 per kWh)
Project Novelty/Strength of Project

Project Overview – Flow Chart

• Chemical composition, physical properties and
morphology data.
• Water permeability data of enhanced
performance concrete.
• Remote monitoring and alert system data.
• Production of off-white biomass silica
– Temperature regime to produce off-white biomass
silica has been identified +- 500°C.
– The off-white biomass silica is about 10 % of the
raw material incinerated.
R&D data

R&D data (Cont’…)
• Amorphous biomass silica
– Blended cement for waterproofing
– High performance concrete
Relation between Coefficient Of Water Permeability
and Age of Concrete for Moist-Cured
2.0E-11
4.0E-11
6.0E-11
8.0E-11
1.0E-10
1.2E-10
1.4E-10
0 7 14 21 28 35
Age (Days)
Coefficient
of
Permeability
(m/s)
OPC
RHA
FLy
TIA
Foamed concrete (1700kg/m3)

– Water permeability of normal weight concrete containing
biomass silica
Types of concrete Water Permeability
(m/s)
Normal concrete without biomass
silica
10-10 ~ 10-11
Normal concrete containing biomass
silica
10-13 ~ 10-14
– Strength development
• 10% to 30% long term compressive strength enhancement

• SEM images of C-S-H gel in the paste with 10%
micronised biomass silica added
• Pore refinement for durability

• Electricity and heat
• Biomass silica
• Remote monitoring and alert system
Project Deliverables

• Working system of rotary reactor furnace
supporting postgraduate studies
• Remote monitoring and alert system in
operation around the clock for the past 6
years.
Status of Prototype

• Differentiated product – off-white amorphous
biomass silica
• Innovative utilisation of agriculture waste to
produce electrical and heat energy
• Supports SREP target – 1 Gigawatts (5-10%) of
the national demand in the form of renewable
electrical energy.
Project/Product advantages

• Local – YTL
• International – Lafarge
• Various importers of silica fume
Competitors

• BioGen (Malaysia) Sdn. Bhd.
– Project Leader
• InvestPerak
– Provides biomass (rice husk), site and
logistics for the venture
• CIDB & UTHM
– Provide 2 patented and 1 patent pending
technologies
(MY140472-A , MY-139642-A and PI20063060)
Contribution/Commitment from the industry
partner

Business model
• Technology licensing to investors, manufacturers and
developers, managed by K-UTECH Sdn Bhd. (Business
arm of UTHM)
• Renewable energy and sustainable development (Perak
Renewable Energy Vision 2020 ???)
• Advisory services from Cradle Fund Sdn Bhd to achieve
the vision of “Catalysing Sustainable Technopreneurs”

Requirements Cost (RM)
Equipment 5,000,000.00
IP Protection 30,000.00
ISO/GMP 70,000.00
Maintenance of Equipment 150,000.00
Pilot Plant setup 350,000.00
Reagents and Consumables 100,000.00
Staff 200,000.00
Training 50,000.00
Travelling 50,000.00
Project Costing (Summary)

• Equipment
500 kW Microturbine Generating System
A biomass gasification system utilising the Combined
Heat and Power (CHP) technology has high efficiency
in power and heat production besides environmental
friendly.
Biomass Handling Equipment
Use for biomass feeding and ash storage
Remote monitoring and alert system
To ensure the consistent performance of the power
plant as well as the quality of the ash.
Project Costing (Justifications)

• IP Protection
• ISO/GMP
• Maintenance of Equipment
For the purpose of continuity and optimum process
of the biomass based power plant.
• Pilot Plant setup
Electrical installation including wiring, metering, and
protection system besides the civil engineering
works.

• Reagents and Consumables
• Staff
• Training
• Travelling
Technology transfer components is to be attached to
the project (Jointly managed by UTHM-CIDB)

• Daily production of 1 kg of off-white
amorphous biomass silica.
Lab Scale (Proof of Concept)

Commercial scale plant
• Target daily production of 10,000 kg of
biomass silica

Risk Assessment
• Financial
– Low (provided incentives for renewable energy approved by
authorities)
– Bonus (if integrated with REKA ALC block plant)
• Technical
– Low (power plant from Finland or Belgium with proven clean energy
track record)
• Timing risk is medium
Risk reduction with strategic alliance with marketing partners and
major developers/contractors/consumers

• PP BioGen JV
– Project Leadership
• InvestPerak JV
– Provides biomass, site and logistics
• CIDB & UTHM
– Provide 2 patented technologies
(Biomass silica and IBS)
Contribution from industry partners

Market need
• 1 GW in RMK-10 derived from renewable energy.
Market size
• Countries with biomass such as Indonesia, Thailand
& Vietnam
• Malaysia alone has potential to produce 250 GW
based on 25 million tonne biomass per year.
Market growth
• 20% per year
Market Demand Potential

Target market
• Power consumption for REKA process
Price competitiveness
• RM0.20/unit against TNB’s minimum rate of
RM0.218/unit
Industry competitors
• Naluri Group ???
Market Demand Potential

Entry barrier
• Patent granted (MY-140472-A) serves as entry
barrier to others
Niche market
• Sustained demand for renewable electricity
based on competitive rate of RM0.20 per unit
???
Competitive advantage

Return of Investment (ROI)
Financial Projection
RM6,000,000
RM2,000,000
RM400,000

Year Project Cash Flow
0 -6,000,000
1 1,600,000
2 1,600,000
3 1,600,000
4 1,600,000
5 1,600,000
6 1,600,000
7 1,600,000
8 1,600,000
9 1,600,000
10 1,600,000
Expected payback period = 4 years
Cash Flow Projection

Return of Investment
Electricity
500 kW x 24 hrs = 12000 kWh = 12000 units
1 unit = RM0.20
12000 units/day x 365 days x RM0.20 =
RM876,000/year.
Biomass Silica Ash
10000 kg/day
1 kg = RM0.30
10000 kg x RM0.30 x 365 day = RM1,095,000/year

Financial forecast
Cash flow
• RM2,000,000 per annum of income for the
500 kW of electricity and ash generated
• RM400,000 per annum for cost of operation
and maintenance
Income projection
• RM1,600,000 to PP BioGen JV

Financial resources
• BioGen internal funding RM200,000
• Soft loan/grant RM5,800,000
Funding

Marketing strategy
• Sale of electricity at RM0.20/kWh to biomass
sources has to be negotiated and agreed
• Sale of biomass silica is proposed to be
RM300/tonne for cementitious IBS products
manufacturers
Marketing strategy

Distribution network
• PP has established network in Malaysia
• Outsource marketing to expedite growth
Capability & Capacity

• Junda Realty Sdn Bhd
Strategic Alliance

Current activities
• Junda Realty is focused on property
development projects
• Development projects with total gross
development value of over RM2.8 billion.
• PP BioGen JV is based on BHB’s (Jati rice)
experience
• BHB’s achievements include Asean Clean
Energy award 2003
Technology/Industrial Partner

Employment
• Boiler man
• Engineer
• Plant operators
• Researchers
Potential Contribution

Export
• Derivatives of biomass silica such as IBS
products and insulation composites
• Nano-particles for specialised markets such as
coatings.
Potential Contribution

Creation of new business
• To become a supplier of off-white amorphous
biomass silica derivatives for high
performance concrete and associated
products
• Leadership in resource-based environmental
technology for Perak
• Carbon neutral development
Wealth Creation

Commitment of Technology/Industrial Partner
• LPN to provide biomass, space and the logistics
for bulk handling of biomass and silica ash
• Operation and maintenance support from PP
BioGen JV

Arrangement with UTHM
• K-UTECH Sdn Bhd, the business arm of
Universiti Tun Hussein Onn Malaysia (UTHM)
will provide the management support services
such as the preparation of agreement
between parties.
• The Research and Innovation Centre of UTHM
will support the project by allowing the
appointment of staff involved in the project.

EXPERIENCES OF CMT MEMBERS
 Assoc. Prof. Dr. Lee Yee Loon is recipient of Cradle Fund (UCIP) for
industrialised construction system (ICS) for road on peat, Past
President of Concrete Society of Malaysia (CSM) and Principal
Research Fellow of RECESS Malaysia. Gold medal winner for the
patented KUIKwall in 2005. Commercialised KUIKwall. 3 PhDs working
on the project.
Assoc. Prof. Dr Mohammad Ali Fulazzaky is developing a biosand
filter with numerous international publications.
 Mr Koh Heng Boon is a structural engineer and senior lecturer of
UTHM who is at the final stage of PhD.
 Mr Chong Chee Hing is Managing Director of Poly Pinnacle Sdn Bhd
who runs a successful drymix business with the brand POLYMIX.
 Mr Jason Soo represents Breton of Italy with vast experience in
stone technology

ICS for road on peat (CradleFund)

PROBLEM
 High cost of construction and maintenance for road on peat
Ground Subsidence:
SMK Deshon, Sibu
Ground subsidence at Jalan Oya Lorong 13

PROPOSED SOLUTION
Pre-commercialisation of:
 KUIK wall, pile, deck, connectors and foamed aggregated as reinforced peat (to
be known as REPEAT©) for road on peat.
 Project site has been identified in a 400 acre development project along Ulu
Oya Road in Sibu, Sarawak.

Selected Publications
• ICET 2007 - Principal Stresses in Non-Linear Analysis of Bakun Concrete
Face Rockfill Dam (International Proceedings)
• MUCET 2008 - Water Permeability of Malaysian Palm Oil Clinker Concrete
• MUCET 2008 - Linear Analysis in Different Construction Stages of Bakun
CFRD
• iCAST 2008 – on Destructive Test of Palm Oil Clinker Concentrate
(International Proceedings)
• Seminar S&T 2008 – Water Absorption by Immersion of Malaysian by-
Product Cement Replacement Concrete
• BICET 2008 – Drying Shrinkage of Cement Replacement Concrete
(International Proceedings)
• BICET 2008 – Water Permeability of Malaysian by-Product Cement
Replacement Concrete (International Proceedings)
• MUCEET 2009 – Foamed Aggregate Pervious Concrete – An Option for
Road on Peat

Selected Publications
• CREAM-UiTM-ACCI-CSM Seminar on Recycling of Construction Wastes for
Sustainable Development
• REAM 2008 - Biomass Silica for Subgrade Modification and Stabilisation
• CEMENTRADE ASIA 2008 – Readymixed Concrete Markets Update in South East
Asia
• MUCET 2008 - Effects of TIA on Water Quality of Cement-Lined Pipes
• CIRAIC 2009 - Controlled Density Pervious Concrete Road On Soft Soil
• Koh Heng Boon, Lee Yee Loon & David Yeoh Eng Chuan “Full-Scale Load Test On
Reinforced Concrete Slab” (World Engineering Congress 2010)2 – 5 August 2010
• Koh Heng Boon, Lee Yee Loon, Chai Teck Jung & Manasseh Voon Yee Kuo
”Compressive Strength and Drying Shrinkage of RBA Concrete” (2010 International
Conference On Sustainable Building and Infrastructure)15 – 17 June 2010
• Lee Yee Loon, Ahmad Mujahid Ahmad Zaidi, Koh Heng Boon & Suhaizad Sulaiman
“Carbonation and Water Permeability of Foamed Concrete” (International Journal
of Sustainable Construction Engineering & Technology, Volume 1-No.1, April 2010,
pp. 33 – 45)April 2010

THANK YOU
ashmann@gmail.com
SEKAM PADI ADA ?
PERAK KAYA !
MALAYSIA JAYA !

Ashmann – affordable concrete

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