Building construction-report (1)

BUILDING CONSTRUCTION 1
[ ARC 1513 ]
ASSIGNMEN T 1 :
Experiencing Construction:
Experiencing, Documentation and Analyzing the Construction Process

CONSTRUCTION REPORT
GROUP MEMBERS
Surayyn Selvan

0309818

Sharifah Diyana

1006AH78373

Soh You Shing

0308010

Meera Nazreen

0309630

Sonia Manyie

0801A65704

Nurul Jannah

0310210

Kee Ting Ting

0310019

Gertrude Lee

0306265

Nasreen Hajibeigy

0310538

TABLE OF CONTENTS
1.0 INTRODUCTION

pg1

1.1 Introduction to the project (MN)
1.2 Introduction to the sites (MN)

pg5

2.0 SITE SAFETY
2.1 Safety Precautions (KTT)

3.0 MACHINERIES AND EQUPIMENTS

pg7

3.1 Types of machineries used (JJ)
3.2 Types of equipments used (JJ)

pg12

4.0 SITE PREPARATION
4.1 Site Clearance & Establishment (GL)
4.2 Earthworks (GL)

5.0 EXTERNAL WORKS
5.1 Sewerage Works (SYS)
5.2 Drainage Systems (SYS)
5.3 Landscaping Works (SYS)
5.4 Fencing Works (SYS)

pg14

TABLE OF CONTENTS
pg19

6.0 TEMPORARY STRUCTURES
6.1 Temporary Supplies (SYS)
6.2 Hoardings (SYS)

7.0 FOUNDATION

pg24

7.1 Foundation Types (GL)
7.2 Foundation Laying Process (GL)

pg26

8.0 SUPERSTRUCTURES
8.1 Beams and Columns (SD)
8.2 Wall Slabs (SM)
8.3 Staircases (SM)

9.0 ROOF

pg34

9.1 Roof Types (SS)

pg37

10.0 SUMMARY (NH)
11.0 REFERENCE LIST

pg40

1

1.0 INTRODUCTION

1.1 INTRODUCTION TO THE PROJECT
!This project requires us, in a group of 9, to select a minimum of one on-going construction site to survey. The site chosen should be a medium rise
building with a maximum of 4-storeys level or a low rise building such as a bungalow house, etc. From the site, we are to identify various types of the building
elements. Apart from that, we need to observe as well as to record the construction process, the details such as the specificatiosn of the materials used,
including the dimensions, sizes and procedures in constructing the components. In addition to that, we need to analyse and explain on how the construction
chosen affect its surroundings.

Our group photo on-site, Fire Station in Jalan Tun Razak

Our group photo on-site, Green Mosque in Cyberjaya

2

1.0 INTRODUCTION
We have decided to survey three sites for this project. This is to allow us to obtain more information on the processes that happen on
the construction sites due to the variation of the types of elements, materials as well as the process in completing the building.

1.2 INTRODUCTION TO THE SITES
1.2.1 Balai Bomba dan Penyelamat, Jalan Tun Razak
!!
!This project was initiated by Jabatan Kerja Raya (JKR) in order to build a fire station in Jalan Tun Razak,

opposite the Tokio Marine Tower. FNA Builders & Services Sdn Bhd were the contractors whom the project was
tendered to. The site is located at Jalan Tun Razak with a size of 1500m₂ equivalent to about 0.6 acres. The building
is an operational building built for firemen to be on a standby shift. The project started construction the 21st
February 2012 and was supposed to be completed on the 20th August 2013. However due to several complications
created by the Industrialized Building System, the project was given an extension of time (EoT) and is now targeted
to be fully erected on the 28th December 2013. This particular project is over 35% upon its completion.
Computer rendering of the completed site

Industrial Building System (IBS)
!Industrialised Building System, or IBS, is used in the construction industry where some or all components

of a building are made in a factory and then assembled on site. In other words, it is a system where buildings are
constructed by the using pre-fabricated components. the components are usually done by machines, formwork and
other form of mechanical equipment that are not on the site. Constructions that use the IBS system are usually
faced with site size and space constraints and therefore on site construction cannot be conducted as the use of
large machineries aren’t allowed.
There are several advantages of the IBS in the construction of buildings, such as the reduction of the
total cost of the construction and the reduction of the amount of workers on site. This will also reduce the number
of foreign workers emplyed on the site. Besides that, the construction period is reduced greatly due to the ease of
erection. Finally, the waste management on site is greatly enhanced due to the minimal use of timber formworks.
The prefabricated concrete structures of the building

Thus, producing a cleaner construction site. Finally, noise is greatly reduced due to the lack of heavy machineries.
!

3

1.0 INTRODUCTION

1.2.2 Cyberjaya Green Mosque, Persiaran Semarak Api
!
!The building of constructing an eco-friendly green mosque is a project that is under the supervision of a

firm called ATSA Architects. It intends to achieve a Platinum GBI rating for this project. The mosque is an
extension of a bigger project which is the new University Islam Antarabangsa campus. The 70819.98m2 site is
situated in Persiaran Semarak Api with a size of which is equivalent to 17.5 acres. The mosque is supposedly to be
able to support a total capacity of 8300 people at a time. Some other facilities that are included in the mosque
that will be build are the parking facilities, a staff quarters which takes up 340m2 of the whole site, a multipurpose
hall with a proposed size of 2376m2 and more. The project is targeting to finish up the whole construction work in
approximately 40 months with its construction beginning in March 2013. As for now, the project is only in its piling
Computer rendering of the completed site

and foundation stages.

The construction zoning and the mosque zone
The construction site in it’s foundation stages

4

1.0 INTRODUCTION

1.2.3 – Terrace Houses, Pandamaran KS5, Klang
!

This project is proposed to construct a residential area made up of double-storeys semi-detached
terrace houses. The site chosen for this project is about 220000m2(22 hectares). There will be a total of 254
units that will make up 22 Blocks. The project started early October 2012 and is expected to be completed by
February 2014. Depending on the location units, they are in different stages of the construction sequence. Some
units are in it’s finishing stages, others were still yet to have their roofing constructed and some are still yet to
have the masonry constructed.
The plastered units of the semi-detached terrace houses

!

The different stages of the units of the terrace houses

The signage outside the site

5

2.0 SITE SAFETY
We are advised to put on safety ware before entering any construction site as it can be dangerous during the progression of the
construction work. There are several ways and methods that should be taken in order to ensure the safety of the construction workers
as well as the site itself. However, it can be seen that some of the sites, have not taken full precautions.

2.1 SITE SAFETY
FIRE EXTINGUISHER
ABC is the most used and most popular multipurpose powder
fire extinguisher for construction site. can be used on class A
(burning solids), B (liquid fires) & C ( Gases fires)

POWER BOX
CORRECTION: electrical area should be covered up with the
electrical box to prevent electricity from losing when it comes
to raining.

CORRECTION: Portable fire extinguishers shall be mounted on a
wall or post at each usable stairway and such that the travel
distance to any extinguisher does not exceed 75 feet.
Mounting height to the top of the extinguisher shall not exceed
5 feet. The general contractor shall ensure that an enough
number of individuals are trained in the proper use of portable
fire extinguishers.

EASY STAIRS

SAFETY SIGNS

Easy Stair are temporary stairs for construction which makes
life much easier on construction sites - allowing the free
passage of men, materials and tools to upper floors without
the danger of climbing ladders.

The safety sign is to keep all the employees safety and aware
of the safety rules with custom safety sign.

CORRECTION: the distorted tread should be fixed. the hook
have to be fixed in one position as it may bouncing up and down
when stepping on it. the railing should be attached together as
well.

6

2.0 SITE SAFETY
2.1 SAFETY PRECAUTIONS

General construction site signs

The board that pinned up with the rules and
regulations for the employees to follow.

Safety Helmet

Economic Safety Vest

Safety helmet is to protect users' head from falling objects.

3-Series Lace Up Safety Boots
Safety boots is to protect the feet from sharp and dangerous objects.

7

3.0 MACHINERIES & EQUIPMENTS
The use of heavy equipment in the construction industry – heavy machines like backhoe, crane and bulldozer – have been increasing due to
high demand fueled by the need to accommodate growth for new constructions, refurbish old projects and buildings, and increased mining
activity to extract raw materials. A major task in any construction operation is the handling of supplies and excavating done by suitable
equipment.

3.1 TYPES OF MACHINERIES USED
BACKHOE LOADER
A backhoe is a mechanical excavator, with the
combined features of a shovel and a dragline.
Primarily used to excavate materials below its
track level like small and large pits, basement,
trenches and survey for underground hazards.
Its commonly used in urban construction
projects, due to its relatively small size and
versatility.

It has the combined features of a shovel and a
dragline. Backhoes are fitted with a dipper in
front and a small backhoe in the back. Instead of
digging away from the machine like a shovel, it
digs towards the machine.

Cab

Backhoe
Bucket

BACKHOE EXCAVATOR
The excavator is equipped with an excavating
bucket that moves in a downward and inward
direction. It is crawler mounted and is best
suited for excavating below track level such as
excavation for trenches and basements.

All movements and functions of the excavator
are accomplished through the use of hydraulic
fluid. It is versatile in the mining, forestry,
construction and pipeline industries.

Cab

Track based crawler

8

equipment.

COMPACTOR (VIBRATORY ROLLER) – SMOOTH DRUM
Vibratory compactor consists of a smooth
drum vibratory rollers and tamping foot
vibratory rollers, widely used for compacting
non-cohesive soils.

They are used to increase the density of
coarse-grained soils. The vibration improves the
compaction of soil and save time when
compared with the static weight method of
compaction.

Smooth Drum

BULLDOZER (TRACK)
The bulldozer is a versatile machine. It can be
used for moving earth up to 100m, stripping top
unwanted soil, clearing and grubbing sites,
excavating to a shallow depth, pushing scrapers,
spreading soil for leveling areas, ripping bare
soft rock and maintaining roads.

Normally track wheeled, dozers excavate and
push earth with the help of a stiff welded steel
blade fitted in front. Backhoe attachments can
also be fitted for ripping hard soil and rock, and
a winch for uprooting trees, skidding boulders
and heavy materials.

Cab

Cutting Edge

9

equipment.

PILE DRIVER (CRANE MOUNTED FRAME – DROP HAMMER)
A piling driver is used to drive piles into the
ground. The frame is mounted on a crane base
for more flexible mobility and it holds the pile
vertical during driving and guides the hammer to
fall vertically onto the pile head.

It uses a large drop hammer that is lifted and
dropped under gravitational force onto the pile
head to drive the piles into the ground, down to
the specific depth set by the engineer.

MOBILE CRANE (TRUCK MOUNTED)
Truck mounted mobile cranes are specially designed
heavy-duty motor trucks to easily transport to a site
and use with different types of load and cargo with little
to no setup or assembly.

They are used to lift medium to heavy loads over high
and wide reaches (i.e. placing precast concrete slabs in
medium rise buildings).

Truck mountings restrict the efficient use of these
cranes to firm, level terrain. This type of mounting
provides a less stable base, higher ground bearing
pressures and poorer on-the-job mobility than the
crawler mounting but has excellent inter-job mobility.

Hoist

Hook Block

equipment.

3.2 TYPES OF EQUIPMENTS USED

HOIST (DEVICE)
Hoists are similar to cranes except that they are
compact and portable. They are used to transport loose
materials vertically in small loads.

CONCRETE DRUM MIXER
Concrete mixer is a machine that combines cement,
aggregate and water to form concrete. Operated either
electrically or mechanically, it is an alternative for mixing
concrete by hand. Concrete discharge by mixer must be
used within 30 minutes before it starts to harden.

10

11

equipment.

3.2 TYPES OF EQUIPMENTS USED

POWER GENERATORS
Generators used fuel such as petrol or diesel to produce
and provide electricity for electrical equipment and site
lights. It allows contractors to continue working without
disruption and meet deadlines.

CIRCULAR ELECTRIC SAW
A circular saw turns a round, flat blade to cut wood,
metal or plastic depending on the blade selected. It is
popular as a woodworking tool because of the time and
labor it saves, precision and it’s ease of handling and
maneuverability. Most circular saws use a cord and plug
connection.

12

4.0 SITE PREPERATION
4.1 SITE CLEARANCE & ESTABLISHMENTS

View of the cleared site in Cyberjaya

View of the cleared site in Cyberjaya

A proper procedure must be done for both site establishment and site clearance. For site establishment, firstly, pre-entry survey must be done before
work commences on the site, preferably a photographic survey supplemented with a written record. Next, advance warning must be done before work begin on site
to make sure that if any parties who will be affected by the works must be notifies of the intention to commence work. Protection to existing structures must
be done to ensure if any structures which cannot be removed for the duration of the works and which may be affected by the works must be protected to avoid
damage. After this, establishment of boundaries is important as it must be treated following the contract to make work safe and secure. Later, any items or
materials which may be re-used on site should be removed and stored in a safe area. Office accommodation, welfare facilities, storage for materials and first aid
were all established after. Next, storage of hazardous materials and establishment of services is done. Lastly for site establishment, it is a must to maintain
boundaries and maintain accommodation.
As for site clearance, reinstatements of the works are done first. Later, when ground is contaminated with unwanted material, this is to be removed
from the site to an approved tip and replaced with uncontaminated materials and disconnection of services must be done. Later, the removal of fencing and
removal of advance warning is done. Lastly, roads and footpaths are checked for cleanliness and fitness for use by the public and where possible photographs
taken.

13

4.0 SITE PREPERATION

4.2 EARTH WORKS

The soil level in Cyberjaya

The flattened compaction of the soil in Cyberjaya

Earthwork at construction site includes grading, which is to modify the site contours according to grading plan for construction, finish grading, which is
the final finished grade according to landscape or paving plan, and excavation, which is to remove soil for working on foundation, pipelines and sewage system,
basement floors.
The project which is still ongoing at Cyberjaya, which is the Masjid Cyberjaya, they use soil compaction. Soil compaction is a method which increases the
density of the soil. The construction project uses mechanical compaction techniques. As for this site, they import a big quantity of soil which is 200000m3 to
the site and for each compaction test, they fill at least 300mm of soil into the ground. For each time they fill in the soil, they do a density test for the compact
soil until it arrive to a certain weight. The total formation height for it is 3m.
It is important to test for the density of the compact soil as poor compaction can result in basement and pool cracks and leaks, slab cracks, pipe leakage
and breaks, foundation erosion, under abutments erosion gullies and utility trench settling.

14

5.0 EXTERNAL WORKS
5.1 SEWERAGE WORKS

Cover

A sewer can be defined as a means of conveying waste, soil or rainwater
below the ground that has been collected from the drains and conveying it to the
final disposal point. The functions of sewerage system are to protecting the
community from flood, restoring clean rivers and fertile waters, creating life
environment and with enhanced amenity. Basically, there are two types of
sewerage systems in Malaysia. The premises' sewerage systems are either
connected to a public sewage treatment plant or have an individual septic tank.
At the residential construction site, all the houses have sewage pipelines that
are directly linked to a sewage treatment plant through a network of
underground sewer pipes.
According to the site manager, there will be a small space outside
the houses to locate the inspection chamber. In the inspection chamber are
sewage outlets from the premises' toilets, bathrooms and kitchen that
are connected to the public sewerage pipelines to the public sewage
treatment plant. The checking and clearing of the blockage will be done via
the inspection chamber if there is any blockage.

Frame

A diagram of an inspection chamber

Inspection cover

600m min diiameter

Private sewerage pipeline from the inspection chamber will be connected
to the public sewerage pipeline. There will be manholes along the public road and it
is usually connected with a round metal cover. In the manholes, which are about 3
meters to 6 meters deep, are sewerage pipes connecting premises to the
sewage treatment plant.

Main drain channel

Branch Ddrain

Typical shallow inspection chamber

15

5.0 EXTERNAL WORKS

5.3 DRAINAGE SYSTEM

Drainage is a system of pipes, generally underground, used to convey
discharge from roofs, paved areas and sanitary fittings to a suitable disposal
installation. The usual method of disposal is to connect to the pipework to the
public sewer, which will convey the discharges to a local authority sewage
treatment plant for processing. Rainwater drainage installation is essential to
collect the discharge from roofs and paved areas and convey it to a suitable
drainage system. It consists of a collection channel, called a gutter, which is
connected to a vertical rainwater downpipe.
Unplasticised Polyvinyl Chloride (uPVC) is used as the material for the
gutter at the residential construction site. . Half-round gutters are supplied in
standard effective lengths up to 6m with a diameter ranging from 75 to
150mm.A few advantages of using the uPVC are it is easier jointing as gutter
bolts are not required and it is light to handle. Besides, it can prevent corrosion
and also fewer breakages.

Rain gutter piping

Half round rainwater
gutter section
Gutter brackets fixed
to fascia at 1.000 c/c
112’ offset or swan-neck
Pipe clip / Holderbat
Rainwater pipe

16

5.0 EXTERNAL WORKS
5.3 DRAINAGE SYSTEM
Surface water runs
away from the building

Ground level
About 3m

Water Table
Impervious level

Ground water runs
away on impervious
layer

Subsoil drainage is applied at the mosque construction site. Subsoil drainage is used to avoid the passage of ground moisture to the interior of the
building and also damage to the fabric of the building. The purpose of subsoil drainage is to lower the water table to a level so that it will not rise to
within 0.25m of the lowest floor of a building. Next, subsoil drainage can increase the stability of the ground, lowering the humidity of the site and
improving its horticultural properties.

17

5.0 EXTERNAL WORKS

5.4 LANDSCAPING WORKS
The landscape work for the mosque construction site is divided into
softscape and hardscape. Softscape refers to the elements found on the
landscape which comprise live and horticultural elements. Hardscape refers to
paved areas and water features, like street and sidewalks.
According to the landscape architect of the construction site, the
landscape will be Tropical and Modern with varieties of local and native plants, like
Cempaka, Kemboja, Pandan, Kemuning and more. Golden chain tree will act as a
welcoming feature at the entrance.
Other flowering tree (Tekoma) will enhance the roadside and other big
canopy trees (Semarak Api, Rain tree, Mambu etc) will act as a shades to the
parking and other open spaces. The hardscape that will be found on site is the
planter box with seating area, water features, Islamic pattern tiles, steps and
more.

Images of the flowering plants

Planter box with seating area
Water features
Islamic patterned tiles
Ablution qrea
Steps
Flowering shrubs

Islamic garden layout plan

Images of the flowering trees

18

5.0 EXTERNAL WORKS
5.5 FENCING WORKS

Diagram of the fencing

The fence is made of brick with cement rendering and there are iron rods coated with paint in between. Full perimeter fencing is installed on the site. The purpose is
to stop or cut down any unwanted pedestrian or vehicular access. At the same time for high level security, the fence was built for high security and maximum
protection.

19

A construction site will need to be set up in whereby temporary welfare facilities are provided for construction workers and staffs, like
toilets, washing facilities, accommodation, waste disposal, car parking, storage and more.

6.1 TEMPORARY SUPPLIES

SITE OFFICE
Site office is actually a portable cabin which is durable
and functional in order to accommodate the intricate demands
of daily work. At the fire station construction site, the size of
the cabin is 6.0m long x 2.4m wide x 2.3m high and it is about
1500kg. Generally, a typical semi-portable site office is 9.6m
or 7.5m long x 3.4m wide x 2.6m high.
The site office in the Pandamaran, Klang site

The site office in the Jalan Tun Razak site

The site offices for this three construction site are
weatherproof, insulated, lit and furnished with desks, work
surfaces, plan and chairs so that it suits the office activity.
The roof is covered with a solar reflective material on profiled
galvanised steel to prevent over-heating.
2.6 m

The site office at the mosque construction site is
much bigger than the other two site offices. A series of
cabins are linked together to form an office complex, with
units delivered fully serviced to fit together.

7.5 m

Standard dimensions of a typical site office
The site office in the Cyberjaya site

20


DISPOSAL BIN
There are different sizes of disposal bin which can be
rented so that workers can throw the waste construction
materials and broken appliances into it. It plays an important
role as it gets rid of the unwanted materials properly without
causing any relative harm to the people around as well as the
environment.
At the fire station construction site, no disposal bin
is found on site. The site manager said that most of the
materials are pre-casted so there are not many waste
material found on site. Thus disposal bin is quite unnecessary.
Although disposal bins can be found at the residential
construction site, rubbish and waste materials are threw
everywhere on site. The site manager stated that there are a
lot of waste materials as most of the materials are cast in
situ. More disposal bins should be placed on site so that the
waste materials can be done more diligently.
On the other hand, as the mosque construction site
is still in foundation stage, not many waste materials are
produced yet but according to the site manager, they will
throw all the waste materials to an empty land near the
construction site.

A typical disposal bin in a construction site

Waste in the Pandamaran site

Waste in the Pandamaran site

21


TEMPORARY SITE TOILET
The temporary site toilet is small as it has a limited
space so it is large enough for a single occupant. Usually, the
dimension of the toilet is about 90 cm (35 inches) square by
210 cm (83 inches) high.
At the fire station construction site, there are only
two temporary toilets for this construction site. One is for
the workers, another one is for the VIP but different gender
shares the same toilet although Urinal, squat toilet and a
water basin are placed in the toilet. They should have provide
separate toilets for male and female instead for VIP.
In contrast, separate toilets for male and female are
provided at the construction site of the residential area and
also the mosque.
SITE ACCOMMODTION
The site accommodation is something similar like the
site office, which is the portable steel container. Standard
units are in 10, 20 or 40 foot long x 8 foot wide. Furthermore,
each unit can be used as a standalone, or in combination by
being stacked on top of each other and joined together to
form a larger space. The stacked units are accessed by a
steel staircase that is connected via a docking point to ensure
the workers safety and high security. One of the benefits
using this portable container is that they are easily relocated.
Although there are around 400 workers working on the
residential construction site, majority of them lives on site.

A reserved toilet for the contractors
The toilet structure in the Jalan Tun Razak site

The site accommodation in the Pandamaran site

22

6.2 HOARDINGS
CONSTRUCTION HOARDING
Construction hoarding is a temporary fencing used to
secure a construction site and it is also a prerequisite for any
developer. The hoarding defines the limit of the site and it is
tall enough to prevent people from climbing or jumping over.
Besides, there is a gate for access and it can be locked when
no one is at the site.
From a safety perspective, construction hoarding
keeps unauthorized personnel out of a site, which reduces the
risk of injury. People without hard hats, safety training, or
awareness of hazards on site like pits and sharp objects won’t
be exposed to danger if they can’t get onto the site without
an escort. Construction firms are responsible for injuries
incurred on site. To reduce the risk of suits from people who
wandered onto a site and were injured, a company may secure
it with hoarding to keep people out and provide clear legal
evidence of a reasonable effort to prevent unauthorized
access.
There are two forms of hoarding are commonly used,
which are vertical and fan hoardings. All the three construction
sites use the vertical hoardings. The vertical hoardings
consist of a series of sheet panels securely fixed to resist
wind loads and accidental impact loads. They are usually freestanding or fixed by stays to the external walls of an existing
building.

Access Gate

100 X 50 braces
1.8 m to 2.12 m

50 X 50 fixing stakes

Typical free standing vertical hoarding

23


6.2 HOARDINGS
CONSTRUCTION STORAGE
The type of storage facilities of any particular material will depend
upon durability, vulnerability to damage from weather and also financial value.
At the fire station construction site, there is no storage for the materials as
most of the materials are precast with the use of “just in time” (JIT) delivery
process thus it reduces the amount of site storage required.
There are a few on site storages can be found on the residential site.
As the storage containers are weatherproof, the workers store some of their
equipment in the storage container so that it is locked for maximum
protection and security purposes. The open storage areas are mainly for the
workers to store bulks and heavy materials. Cement and plaster which are
supplied in a bag form are stored in a dry store as the moisture in air may
cause an air set of material.
Storage containers in Pandamaran, Klang

Roof tiles have a greater resistance to load when they are laid on
their edge so it is correct that the workers at the residential construction
site stack the tiles on edge and in pairs, head to toe to give protection to the
nibs that they hang on. They should have use the shrink-wrapping to ensure
that the tiles are secure until loaded onto the roof for fixing.

The correct and incorrect arrangement of the roof tiles

24

7.0 FOUNDATION
6.2 FOUNDATION TYPES

The metal cap which
the pile driver will knock

Piles can be described as a structural stilt hammered into the ground. The
type of pile used at this Masjid Cyberjaya site is 250 x 250 reinforced concrete
(RC) piles. Each of these piles has a sheet plate on top of it. These sheet plates help
to drive the pile in the ground without damaging the RC pile.

The blue markings

The markings on the pile are used to help see the depth of the pile caps. For
this project, the depth of the pile which is driven into the ground was about 12 m
deep. The remaining of the RC pile which is extruding out from the ground is being cut
off. These remaining which were cut off are crushed and used as foundation. Piled
foundation is being used in this construction site.
Piled foundation is a foundation that enables a structure to be supported
by a layer of soil found at any depth below the ground surface. A pile foundation has
two basic structural element which is pile and pile cap. Pile cap is a structural base
that supports a structural column, wall or slab, similar to spread footing. Pile cap
bears on single pile or group of piles. The type of piling used can be classified as endbearing pile.

The pile cap

Diagram of a pile foundation

A test is also done to test the weight for the column load. Blocks of big
concrete is stack up above each other to a certain amount of concrete and height in
order to test the weight. A gauze reading is used to take the reading. The workers
would have to stay there for at least 3 days in order to get the readings of the
test for the weight of the column load.

Load testing structure

25

7.0 FOUNDATION

6.2 FOUNDATION LAYING PROCESS

The remaining cut RC piles are crushed
and used as foundation

A steel mat is laid and formed in the shape of the
pile

Timber is set around the steel met to
contain the wet concrete mix

Pile cap is made out of aggregate of small rocks and cement but in this case, for this site, they use the remaining cut-off piles as the material for the
foundation. They crush the remaining cut-off piles and used them as foundation. As to avoid sagging and fracture whilst setting, the mixture has to be supported
by framework. This process is known as shuttering and reinforcing. The materials used to make the steel mat are long twisted steel bars between the piles and
thinner tie wires. Once the steel mat is done, the timber is attached around the steel mat in order to complete the framework before pouring in the wet concrete
mixture. Once the wet concrete mixture is poured, the concrete has to be stirred in order to remove air pockets which might weaken the structure. Chemical
changes that is happening in the concrete would help to harden the concrete and at the same time, it will produce heat.

26

8.0 SUPERSTRUCTURES
8.1 BEAMS AND COLUMNS
Beams and columns are frequently used for a building's structure as a
replacement for steel. They are commonly used for precast building solution,
when combined with precast walling and flooring. This method is used in
constructing the Jabatan Balai Bomba dan Penyelamat at Jalan Tun Razak.
The structural precast columns are reinforced and can be used as a
part of a total precast concrete structure. A variation of finishes can be
applied according to the building type once the beams and columns are done.
Beams are commonly used as ledges for other forms of precast flooring to
rest on, but can also be used as a flooring option on their own. They are
manufactured to suit each particular building design. Some of the beams
included are Tee-Beams, L-Beams, Rectangular Beams, U-Beams and Beam
shells.

The post and lintel
joints of the beams
and columns
Wooden planks are used
to hold the structures
together temporarily
The wall slabs are
grouted to the columns

Assembly of precast concrete columns and beams

Steel reinforcements
are place inside the
precast columns and
beams to further
enhance their strength
capabilities

Joint between columns
and beams are drypacked with grout after
alignment

Before assembly

Reinforcement of the concrete

Assembled

Grouted

Process of the connection of precast columns

27

8.0 SUPERSTRUCTURES

8.1 BEAMS AND COLUMNS

However, the most common method of constructing beams and columns
are through in situ cast concrete. This method can be seen in the construction
of the Green Mosque in Cyberjaya. The beams and columns are built on site and
are affected by the site conditions. Weather plays a major role in the
construction process as it can cause detrimental effect if precautions are not
taken. The in-situ concrete structure mostly contains steel reinforcements for
stronger support. The steel reinforcements are placed in between the concrete
during casting.

Steel reinforcements
set up in the formworks

The timber formwork to
hold the wet concrete
mix

Concrete formworks

Steel reinforcement

Concrete

Steel reinforcements placed inside the timber formwork
Section of a column

28

8.0 SUPERSTRUCTURES
8.2 WALL SLABS
HOLLOW CORE COMPONENTS
The primary physical difference between this type of element and
solid flat components is the void. Hollow-core slabs are lighter and structurally
more economical and efficient. Moreover, they can carry more load and span a
longer distance while having a small cross-section. However, its lack of weight,
mass and the limited distance between floor-to-floor height which prevents it
from being used as a long member makes it less practical and economical for
wall members.
Hollow core
section

Hollow core wall slabs on site

Void

PRECAST HOLLOW CORE WALL PANELS
Pre-stressed bar

Post-tensioning
conduit

Hollow core wall slabs grouted together on site

Concrete

There are modifications that can be done to the hollow-core system as it
is adapted to be used as wall panels while maintaining their advantages.
The essential components of this system includes two types of hollow-core slabs.
These are the standard pre-stressed hollow-core slab and the partially prestressed hollow-core slab with post-tensioning conduits.
The wall panels can be made in the same form and by the same
manufacturing method similar to the standard pre-stressed hollow-core slabs.
Hollow-core wall panels have been used in some structures in 8’ to 9’ long members.
However, three modifications are required in order to be able to use hollow-core
slabs practically and economically as wall panels.

29

8.0 SUPERSTRUCTURES

8.2 WALL SLABS

BRICK WALLS
Brick Walls is masonry produced by brick layering which uses bricks and mortar. They are rows of bricks laid on top of each other building up a structure of
a wall. This is used in the Pandamaran, Klang construction site. The joint of any two bricks is usually filled with mortar. The style of mortar joints used in this
particular brick wall is the recessed joint which basically leaves the edge of the brickwork exposed. The arrangement of the bricks also comes in different bond
patterns. The bond patterns that are used in this structure are a mixture of English bond and Flemish bond.

Recessed joints which
are raked out leave the
edges of the brick
works exposed.

English bond pattern which is
made up of alternating
stretchers and headers. It
is easy to lay and is one of
the strongest bond.

Due to this wall being
the interior and it is
going to be cemented,
the workmanship is
relatively poor.

Flemish bond which is
alternating layering
stretchers and headers in a
single course.

Recessed joints
Brick bond patterns

8.0 SUPERSTRUCTURES
8.2 WALL SLABS

First, pre-stressed tendons should be added at the top of the slab and some
being eliminated at the bottom during manufacturing in order to secure
symmetrical forces in the cross-section of the unit. Then, some or all the voids
should be eliminated in order to achieve a more solid section for compressive
forces. Two of the eliminated voids in the wall panel should be perpendicular to
the post-tensioning conduits in the floor panel.

Equal wall panels and the varying wall panels

Finally, holes should be provided to enable the slab’s post-tensioning
rods to pass through. The holes can be drilled in the factory after
manufacturing.

Moreover, the walls can be put beside each other, vertically, in two
basic patterns. The pattern is when the height of the wall panels should be equal
at each level of erection .The second pattern is when the height of every panel
other panel should vary in one story increments. This method adds support and
rigidity when construction continues in height.

The wall panels in the Jalan Tun Razak site is almost similar in height

30

31

8.0 SUPERSTRUCTURES

8.3 STAIRCASES
The types may be straight run, platform or winding. The platform type includes landings where the direction of the run is usually changed. In two of the sites, both
staircases are of the platform type. However the construction method and type of platform staircase varies.

HALF LANDING STAIRCASE
The pre-casted staircase in the Jalan Tun Razak Fire Station is a half landing
staircase. Here the landing changes a direction of the flight by 180 degrees and
serves as a place for rest when moving. The landing divides the staircase into two,
thereby reducing quantity of treads in one flight and consequently making walking
more comfortable.

STRAIGHT STAIRS
In the Pandamaran site, the concrete cast in-situ staircase can be seen as a
straight staircase with a mid landing platform. The straight run stairway is
continues from one floor level to another without landings or turns. Despite being
easiest to build, a long run of 12 to 16 steps also has the disadvantage of being
tiring as if offers no chance for a rest during ascent.

32

8.0 SUPERSTRUCTURES
8.3 STAIRCASES
Support
Landing

Return
Landing

The front of the
tread usually has a
nosing
The bottom of the
stairs is the soffit

The concrete stairs
have to slop
forwards for
drainage is usually
The tread

The depth of the
soffit is called the
throat

Support
Landing

given a float finish
semi rough

The footing has to
rest on bearing
ground
Concrete stairs cast in-situ assembly

Pre-cast concrete assembly

33

8.0 SUPERSTRUCTURES

8.3 STAIRCASES

Single step riser on the
first flight of stairs

The flight of staircase is the set of steps between one floor or landing and the next. According to the Malaysian Building By-law, no part in any flight of
staircase is allowed to have less than two risers. However it is seen here in the Pandamaran, Klang construction site that the first flight of staircase only
consists of a single step which means that the design does not abide by the law. This may cause danger to the user as they tend not to see them and get
confused. If a single step were allowed, it would require a handrail. This is because handrails gives the users a visual sense of how long the stairs are.

34

9.0 ROOF
9.1 TYPES OF ROOFS
MONOPITCHED ROOF

A monopitched roof, also commonly known as the lean-to roof, is a roof
structure that has one sloping surface and the sloped surface does not rest on any
from of wall on the opposite ends. Monopitched roofs encourage good drainage during
rainy weather as well as aiding in reflecting heat away from the building if oriented
appropriately. Usually the larger opened end is oriented facing away from the sun to
ensure that sunlight and heat gain is reduced. It is one of the easiest roof
structures to build and requires less cost. The fire station roof is composed of a
concrete surface that rests on a lightweight roof truss made our of foam core
steel. Due to it being an IBS based building, the roof components are delivered and
the structure is fabricated on site.
The fire station in Jalan Tun Razak with several monopitched roof structures

Pitching point

Gutter

Steel bars
Soffit

Concrete wall with
aluminum cladding
Howe truss roof structure
A sectional cut of the roof structure

35

9.0 ROOF

9.1 TYPES OF ROOFS
DUALPITCHED ROOF
A more commonly used type of roof in residential areas, the dual pitched
roof, is a roof structure that has two sloping surface that form an upside down “V”.
Similar to the function of the monopitched roof, the sloped surface ensures proper
drainage during rainy weather. The Pandamaran terrace houses uses the Gable
shaped dual pitched roof structure. Similar to the Jalan Tun Razak Fire Station, the
same material is used as the truss. Lightweight roof trusses were used to create a
Double Howe Truss. This enables the building to hold heavier ceiling loads while
withstanding a span of about 20 to 50 feet. Terracotta coloured concrete tiles
were used for the roof tiles.
The terrace houses using the Gable dual pitched roof

Ridge

Fire resistance
barricade

Rake

Gable
Fascia board

Half round gutter
Soffit

Double Roman
Concrete TIles

Angled Ridge Concrete Tile

Components of a dual pitched Gable roof structure

36

9.0 ROOF
9.1 TYPES OF ROOFS

•  Water tank
placed on top
of steel hollow
core joists
•  A wooden plank
is placed
underneath to
prevent the
tank from
becoming
distorted when
water is added

Ridge

Exposed Double Howe roof truss without the bottom chord

Rafters
Webs

Post
Bottom
chord
Components of a Double Howe roof truss
The components were attached by being bolted to each other

37

10.0 SUMMARY

10.1 CONSTRUCTION ORGANIZATION

Throughout this project we’ve come to the conclusion that in the construction
industry, organization and proper planning of work is needed. The architects and contractors
also have to abide by the Malaysian Building By Law book to ensure that the respective
buildings are following the guidelines. We were very lucky to have visited three very different
sites and each site had a different approach to their organization and planning.
Firstly, the Jalan Tun Razak fire station is constructed based off the Industrialized
Building System where most of it’s components are prefabricated. In an IBS construction,
the project’s construction duration should be reduced due to the ease of construction as
well as the speed of the making of it components. However, in this case it is not. They were
expected to finish the project on the 30th of August 2013 but due to poor construction
management an extension of time was given and it is now expected to be completed in
December 2013.

Gantt Chart of the Jalan Tun Razak Fire Station

Another major flaw in the project management was the planning of the Gantt chart.
The slope of the lines are supposed to decrease gradually and not have a steep drop. The
Gantt chart is essential in a construction project because it shows the start and finish
dates of the major elements in a project while showing the dependency relationship between
the activities.
In the Green Mosque in Cyberjaya, the Gantt chart was much more well planned as
the slopes were gradual and there were no major steep drops. A major reason for this is
because the Green Mosque intends to achieve a Platinum GBI rating and in order to do so,
the planning as well as the organization of the project has to be in top shape.
Gantt Chart of the Green Mosque in Cyberjaya

38

10.0 SUMMARY
10.1 CONSTRUCTION ORGANIZATION

Physical S-Curve for the Jalan Tun Razak Fire Station for the month of July

Physical S-Curve for the Green Mosque in the month of June

Another major element in the organization and planning of a construction project is the S-Curve. The S-Curve is to determine whether or not the
construction project is on the right track or if it is behind schedule. If the construction project is a successful one, the S-Curve would look more like and “S”
shape and it would finish behind the set track of schedule. In an S-Curve, there are two lines, one is the line which is the pre-planned schedule of the related topic
and the other is the actual line of the schedule. At the bottom of the S-Curve there is a table to calculate how far behind a project is from the planned schedule.
If a project is behind schedule, a negative percentage will be calculated if a project is ahead on schedule it will be a positive number
There are many types of S-Curves in a construction projects such as one for finance and there are ones that are conducted weekly, but for this example
we’ll focus on the physical progress of the sites monthly. It can be seen that in the month of July, the Jalan Tun Razak Fire Station is way behind schedule where
the only time they’ve hit the schedule is in the early parts of a project. As of 31st of July, they are -1% behind schedule. However, for the Green Mosque in
Cyberjaya, it can be seen the actual line is on the same track as the pre-planned line. This shows that the project is on schedule and is due to finish on time, if not
earlier.

39

10.0 SUMMARY

10.3 WASTE MANAGEMENT
Waste management of a site is also an essential part in a construction project as it
shows the architects compassion for mother nature. There are many ways to organize
waste products on a construction site and 2 out of 3 of our sites did not take the initiative
to organize their waste materials appropriately.
Firstly, in the Fire Station in Jalan Tun Razak. Due to it being an IBS construction,
waste materials were at a bare minimum. However, they were excess formworks and steel
reinforcements that were left unattended to in the site. It is understandable that they lack
space in the site and might not have the capacity to house a central waste repository.
Nonetheless, an initiative should be taken in order to properly organize and dispose of the
waste materials.
The most unorganized site was the site in Pandamaran, Klang. The 22 acre site was
terribly managed in terms of its waste organization. In between houses, piles of formwork,
excess concrete roof tiles, aggregate, aluminum frames and excess brickwork were found
piled up. This made it very hard to navigate through the site efficiently as some parts were
hard to access due to the overwhelming number of waste materials blocking the access
routes. It would be recommended for a big site to zone out a space for the organization of
waste materials so it would be easier later on for them to conduct their external works.

The alley way of the terrace houses

The most well planned site was the Green Mosque in Cyberjaya. Due to it wanting to
achieve a high rating for the Green Building Index. Measures were taken to ensure that no
waste material on site was unorganized and gone to waste. For example, the excess pile caps
were crushed and were later used as foundation. Besides that, they have taken the initiative
to segregate the waste materials in a central waste repository on site. We were also
informed that before construction everyday, the workers will be reminded of these measures
so it will be effectively carried out.
An area in the Pandamaran site

The Jalan Tun Razak site

11.0 REFERENCE LIST
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http://www.nhbc.co.uk/NHBCPublications/LiteratureLibrary/Technical/filedownload,
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Chudley, R., Greeno, R., Hurst, M., & Topliss, S.. (2011). Construction
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Publishing Company Limited.
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Available at: http://heavyequipment.com [Accessed: 9 Oct 2013].
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Headquarters, Department of the Army. http://books.google.com.my/
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Oct 2013].
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40

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Container Accommodation: Site Offices, Site Canteens. (n.d.). Storage & Shipping Containers for
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