NICMAR
CONSTRUCTION TECHNIQUES IN A HIGH RISE BUILDING
SUBMITTED TO:
SUBMITTED BY:
Prof.J.Soneji Prof.J.Sonej i
S.Naraana Raj! "#$%#$&' S.Si(a Tar!n
"#$%#)*'
An!+ee, Ra(i-eja"#$%*' Ra(i-eja"#$%*'
NATIONAL INSTITUTE O/ CONSTRUCTION CONSTRUCTION MANAGEMENT AND RESEARCH
PUNE
ABSTRACT: Buil Buildi ding ngss are are beco becomi ming ng high higher er and and high higher er nowad nowaday ayss in maxi maximi misi sing ng land land use use and and investment return.Construction of high rise residential developments are considered as a focal point of the construction industry in view of its huge labour contents and turnovers evo evolved ved due to its its own natu ature of wor ors and and inves vestmen tments ts inv involved lved fro from the investors.Investors tend to build everything possible in a small piece of and to increase the retu return rn from from thei theirr inve invest stme ment nt in the the !uic !uice est st poss possib ible le mann manner er." ."ra ract ctic icio ione ners rs in the the construction construction industry are looing for different means and methods in enhancing effeiciency and meeting re!uirements from the stautory bodies and the clients.#he purpose of this thesis is to loo into the considerations re!uired nowadays in construction planning for construction of high rise buildings. A complementary relationship exists between technology and constructivism$ the implementation of each one benefiting the other.#he public nature of a high rise building can can be und unders erstoo tood in two way ways.%i .%isual ually it is an exp expressi essio on of arch archit itec ecttural ural imag imager ery y."hys ."hysic ical ally ly it is a layo layout ut of atta attach ched ed publ public ic spac spaces es in whic which h peop people le can can interact.Recently high rise buildings have grown in terms of their asthetics as well as their heig height ht.& .&it ith h the the aid aid of vari variou ouss tech techno nolo logi gies es of high high rise rise buil buildi ding ngss the the symb symbol olic ic representation and the public nature of high rise buildings are examined.In addition the Cambridge house and Marvel's Brisa case studies are illustrated to show that high rise buildings buildings is moving towards towards a focus on construction construction technology technology and building style. style. #he study of these technologies for high rise buildings provides a basis for method that would serve as a basis in predicting the technology that would be most suitable in the current Indian scenario which is heading rapidly towards vertical development.
2
INDE0 Con1-r!2-ion of Hi34 Ri1e B!i5+in31 C4a,-er Na6e
Pa3e No
Chapter( ) Introduction
*
).) +b,ective of -tudy ). / -cope of -tudy ). 0 Need of -tudy ).* Methodology
1
Chapter (/ 2 3I#4RA#5R4 R4%I4&
6
/. /.) Introduction 6 /./ 3iterature Review 6 /.0 "recast Concrete Construction 7 /.* Categories of "recast Building -ervices )8 /. 3arge "anel -ystem )8 /.1 9rame -ystem )0 /.: -lab(Column -ystems with -hear walls )* /.6 4arth!uae "erformance ): /.7 -eismic -trengthening #echnologies )7 /.)8.) Introduction /8 /.)8./ Component #echnologies of 3arge -ystem /8 /.)8.0 +utline of -ystems /) /.)8.* 3ift up -ystems /) /.)8. Automated Conveying -ystems /) /.)8.1 Automated -teel Assembling -ystems // /.)8.: Automated &elding -ystems // /.)8.6 Automated #ransportation and Installation of "refabricated Materials and 4!uipment // /.)8.7 Information Controlling -ystems /0 /.)8.)8 A pplication of the -mart -mart -ystem in Construction of the Nagoya ;urou Ban Building /.)8.)) Construction "rocedure
/0 /0 3
/.)8.)/ 4ffects of -ystems /.)8.)0 Conclusion
/0 /
C
08
0.) Articles and Boos 0./ &ebilography
08 0)
CHAPTER7% 4
%.INTRODUCTION:
According to the statistics from the Indian government the area of the country is about 0$/6:$/10 s!.m.#herefore$land resource is very vital to the Indian people.In such a case$a high rise building provides space for people and their activities.In India$land is very limi limite ted d and and the the gove govern rnem emen entt spen spends ds many many reso resour urce cess to upgr upgrad adee the the hous housin ing g conditions.#herefore$ developer=owner will construct building as big >large floor area and high rise? as they can.many technologies are used in high rise buildings >eg. "restressing beam and slab$ high strength concrete?.-ince devoplers also borrow money from ban to buy the land @therefore$ @therefore$ they will use use a !uicer method method to use the interest. interest. Many technologies high rise buildings have fasinated manind from the beginning of civili civilisat satio ion.# n.#he he egypti egyptian an pyram pyramids ids$$ one amoun amoung g the seven seven wonder wonderss of the world world$$ constructed in /188B.C. are amoung such ancient high rise buildings. -uch structures were constructed for defence and to the prode of the population in their civilsation.#he growth in modern modern multist multistorey oreyed ed building buildingss construc construction tion$whi $which ch began in the late )7 th centuary centuary is intended largely for commercial and residential purposes. 5ndeniably the high rise building is seen as a wealth generating mechanism in an urban ecenomy.
%.%.OBJECTI8E O/ STUDY: 5
#o study the different construction techni!ues lie cast(in(situ and precast adopted by ma,or players for high rise development$ analyse and compare them to determine the ones that would be most suitable in the Indian high rise construction construction scenario.
%.#.SCOPE O/ STUDY:
#he study encompasses the analysis of construction techni!ues used for high rise buildings buildings which would be be suitable for large large scale used in the Indian Indian scenario.
%..NEED O/ STUDY:
#he development of the high rise building has followed the growth of the city closely.#he process of urbanisation that started with the age of industrialisation is still in progress in developing countries lie India.Industrialisation India.Industrialisation causes migration of people to urban centres where ,ob oppurtunities are significant.#he land available for buildings to accomo accomodat datee this this migr migrati ation on is becom becoming ing scarce scarce$$ resul resultin ting g in rapid rapid incre increase ase in cost cost of land.#hus developers developers have looed towards the sy to mae their profits.#he results is multi storied building$ building$ as they provide a large floor area in a relatively small area of land in urban centres. #heir #heir is enoug enough h demand demand for for high high rises rises for for both$ both$ reside resident ntial ial and commer commercia ciall spaces spaces.#h .#here ere is no reason reason to believ believee that that the the demand demand is short short term.# term.#he he demand demand for developments is seen for residential$ commercial$ retail and hospitaility too.
%.* METHODOLOGY: 6
CONSTRUCTION TECHNIQUES IN IN A HIGH RISE
Purp!"#S$p" D"%&'&(&'
AIMS,OBJECTIVES,N
D"%&'&(&' % H&)* r&!" +u&-&')!
LITERATURE STUD
H&!(r. /'- "0u(&' % *&)* r&!" +u&-&')!
D"0"p1"'(, r"/!'! %r -"0"p1"'(, /-0/'(/)"! /'-r/+/$! % *&)* r&!" +u&-&')!
D"!&)' C'!&-"r/(&'!
T"$*')&"! /0/&/+" % $/!(&'!&(u, !("" /'- pr"$/!( 1"(*-! ANALSIS
C1p/r/(&0" /'/.!&! % (*" T"$*')&"!
7
8C/1+r&-)" Hu!" 2M/r0"9!Br&!/, Pu'"
CASE STUD
C'$u!&' /'- %u(ur" !$p"
CHAPTER -2
LITERATURE RE8IE9
#.% INTRODUCTION
Buildings are becoming higher and higher nowadays in maximising land use and investment return.Construction of high rise residential developments are considered as a focal point of the construction industry in view of its huge labour contents and turnovers evo evolved ved due to its its own natu ature of wor ors and and inves vestmen tments ts inv involved lved fro from the investors.Investors tend to build everything possible in a small piece of and to increase the retu return rn from from thei theirr inve invest stme ment nt in the the !uic !uice est st poss possib ible le mann manner er." ."ra ract ctic icio ione ners rs in the the construction construction industry are looing for different means and methods in enhancing effeiciency and meeting re!uirements from the stautory bodies and the clients.#he purpose of this thesis is to loo into the considerations re!uired nowadays in construction planning for construction of high rise buildings.#he following are the research done by eminent people in the field of developing new technologies in the building of high rise buildings.
#.# LITERATURE RE8IE9
According to -vetlana BrDev$ British British Columbia Institute Institute of #echnology$ #echnology$ and Canada #eresa Euevara("ereD$ Architect$ %eneDuela did research on the precast concrete construction and published the papers in the following ,ournals. ,ournals.
)? efinition of @Mass "roduction "roduction in @Industrial @Industrial 4ngineering and "roduction Management Britannica Macropaedia$ The New Encyclopaedia Britannica$ )th 4dition$ %ol. /)$ p. /8*$ )767. /? 5NI+$ )760. esign and Construction Construction of "refabricated Reinforced Concrete 9rame and -hear(&all Buildings. Building Construction 5nder -eismic Conditions in the Balan Region. %olume /.5N"=5NI+ "ro,ect R4R=:7=8)$ R4R=:7=8)$ %ienna$ Austria. 0? 44RI >)767?. Armenia 4arth!uae Reconnaissance Report. -pecial -upplement to 4arth!uae -pectra$ 4l Cerrito$ California.
:
2.3 PRECAST CONCRETE CONSTRUCTION
#he concept concept of precast precast >also nown as @prefabri @prefabricated cated? ? construc construction tion includes includes those those buildings where the ma,ority of structural components are standardiDed and produced in plants in a location a way from the building$ and then transported to the site for assembly. #hese components are manufactured by industrial methods based on mass production in order to build a large number of buildings in a short time at low cost. #he main features of this construction process are as follows2 F F
#he divi divisio sion n and spec special ialiDa iDatio tion n of the the human human worf worforc orcee #he use use of tools tools$$ machiner machinery$ y$ and other other e!uipm e!uipment ent$$ usually usually autom automated ated$$ in the production production of standard$ interchangeable interchangeable parts and and products
#his type of construction construction re!uires a restructuring restructuring of the entire conventional construction construction process to enable interaction interaction between the design phase and production production planning in order order to improve and speed up the constru constructio ction. n. +ne of the ey premises premises for achievin achieving g that ob,ective is to design buildings with a regular configurationin configurationin plan and elevation. 5rban residential buildings of this type are usually fiveto ten stories high >see 9igures ) and /?. Many countries used various precast building systems during the second half of the /8thcentury to provide low(income housing for the growing urban population. #hey were very popular after the -econd &orld &ar$ especially in 4astern 4uropean countries and former former -oviet -oviet 5nion 5nion republ republics ics.. In the the forme formerr -oviet -oviet 5nion$ 5nion$ differ different ent precas precastt buildings systems are denoted as @-eria$ whereas in Romania they are called @-ecGiunea. In general$ precast building systems are more economical when compared to conventional multifamily residential construction >apartment buildings? in many countries. #he reader is referred to the 5NI+/report for detailed coverage on precast systems and their earth!uae resistance.
Figure 1: Typical large-panel buildings in Kyrgyzstan Kyrgyzstan (WHE Report 38 and Russian Federation (WHE Report !!
8;
Figure ": # typical typical precast slab-colu$n building (WHE Report %8& 'erbia and ontenegro
#.* CATEGORIES O/ PRECAST BUILDING SYSTEMS
"recast buildings constitute a significantfraction of the building stoc in the republics of the former -oviet 5nion and 4astern 4uropean countries. #hese systems have been desc descri ribe bed d in the the foll follow owin ing g eigh eightt &<4 &<4 repo report rts2 s2 0/ >HaDa >HaDah hst stan an? ? 00$ 00$ 06$ 06$ and and 07 >HyrgyDstan? >Russian 9ederation? 11 >5Dbeistan? 16 >-erbia and Montenegro? and 60 >Romania?. epending on the load(bearing structure$ precast systems described in the &<4 can be divided into the following categories2 F F F F
3ar 3arge(p e(panel anel syst system emss 9rame systems -lab -lab(c (col olum umn n sy system stemss with with wall wallss Mixed systems
)
#. Lar3e7Pane5 S1-e61
#he designation @large(panel system refers to multistory structures composed of large wall and floor concrete panels connected in the vertical and horiDontal directions so that the wall panels enclose appropriate spaces for the rooms within a building. #hese panels form a box(lie structure >see 9igure 0?. Both vertical and horiDontal panels resist gravity load. &all panels are usually one story high.
Figure 3: # large-panel concrete building under cons constr truc ucti tion on (WHE (WHE Repo Report rt !!& !!& Russ Russia ian n Federation
epending on the wall layout$ there are three basic configurations configurations of large(panel buildings2 buildings2 F F
F
Cross( Cross(wal walll system system.. #he main walls walls that that resist resist gravi gravity ty and later lateral al loads loads are placed placed in the short direction of the building. 3ongitud 3ongitudinal( inal(wall wall syst system. em. #he walls walls resis resisting ting gravity gravity and and lateral lateral loads loads are are placed placed in the longitudinal direction usually$ there is only one longitudinal wall$ except for for the syste system m with with two longit longitud udina inall walls walls develo developed ped in HaDah HaDahsta stan n >&<4 >&<4 Report 0/?. #wo(way #wo(way system. system. #he walls walls are placed placed in in both both direct directions ions >Romania >Romania$$ &<4 Repor Reportt 60?.
#hicness of wall panels ranges from )/8 mm for interior walls >HyrgyDstan$ &<4 report 06? to 088 mm for exterior walls >HaDahstan$ &<4 Report 0/?. 9loor panel thicn thicness ess is 18 mm >Hyrgy >HyrgyDst Dstan? an?.. &all &all panel panel length length is e!ual e!ual to the the room room length length$$ typically on the order of /.: m to 0.1 m. In some cases$ there are no exterior wall panels and the faJade walls are made of lightweight concrete >Romania$ &<4 Report 60?. A typical interior wall panel is shown in 9igure *.
Figure *: +recast interior ,all panel ,it steel do,els and groo.es (WHE Report 38& Kyrgyzstan
"anel connections represent the ey structural components in these systems. Based on their location within a building$ these connections can be classified into vertical and horiDontal ,oints. Vertical joints connect the vertical faces of ad,oining wall panels and primarily resist vertical seismic shear forces. Horizontal joints connect the horiDontal faces of the ad,oining wall and floor panels and resist both gravity and seismic loads. epending on the construction method$ these ,oints can be classified as wet and dry. Wet joints are constructed with cast(in(place concrete poured between the precast panels. #o ensure structural continuity$ protruding reinforcing bars from the panels >dowels? are welded$ looped$ or otherwise connected in the ,oint region before the concrete is placed. Dry joints are constructed by bolting or welding together steel plates or other steel inserts cast cast into into the the ends ends of the the precas precastt panels panels for this purpos purpose. e. &et ,oints ,oints more more closel closely y approximate cast(in(place construction$ whereas the force transfer in structures with dry ,oints is accomplished accomplished at discrete points. points.
9igure shows a plan of a large(panel building from HaDahstan with the connection details. In this system$ vertical wall panel connections are accomplished by means of groove groove ,oints ,oints$$ which which consis consistt of a contin continuou uouss void void betwee between n the panels panels with with lappi lapping ng horiDontal steel and vertical tie(bars. &<4 Report 60?. Boundary elements >called @bulbs in Romania? are used instead of the columns as @stiffening elements at the exterior$ as shown in 9igure 1. #he unity of wall panels is achieved by means of splice bars welded to the tran ransver sverse se reinf einfo orcem rcemen entt of ad,a ad,ace cen nt panel anelss in the ver vertical ical ,oi ,oints nts. 3ongitudinaldowel
Figure !: +lan o/ a large-panel buil buildi ding ng so, o,ing ing .ert ertical ical connection details (WHE Report 3"& Kaza0stan
Figure %: # typic typical al buildi building ng plan so,ing te locations o/ boundary $e$bers $e$bers (WHE Report 83& Ro$ania
bars placed in vertical vertical and horiDontal ,oints ,oints provide provide an increase in bearing bearing area for the transfer of tension across the connections. &all(to(floor connection is similar to that shown in 9igure . #.; /ra6e S1-e61
"recast frames can be constructed using either linear elements or spatial beam(column sub assemblages. "recast beam(column sub assemblages have the advantage that the connecting faces between the sub assemblages can be placed away from the critical frame frame regio regions ns howev however$ er$ linear linear elemen elements ts are genera generally lly prefe preferre rred d becaus becausee of the the difficulties associated with forming$ handling$ and erecting spatial elements. #he use of linear linear elemen elements ts genera generally lly means means placin placing g the connec connecti ting ng faces faces at the beam(c beam(col olumn umn ,unctions. #he beams beams can be seated on corbels at the columns$ for ease of construction construction
Figure : 2o$ponents o/ a precast rein/orced concrete /ra$e syste$ o/ 'eria '-4* (WHE Report %%& 5zbe0istan
and to aid the shear transfer from the beam to the column. #he beam(column ,oints accomplished in this way are hinged. -eria )81? is an example of a frame system with precast beam(column sub assemblages >HyrgyDstan$ &<4 Report 00?. #he system was developed in HyrgyDstan in )7:. #he load(bearing structure consists of a precast reinforced concrete space frame and precast floor slabs. #he space frame is constructed using two main modular elements2 a cruciform element and a linear beam element >9igure 6?. #he cruciform element consists of the transverse frame ,oint with half of the ad,acent beam and column lengths. #he longitudinal longitudinal frames are constructed by installing the precast beam elements in between the transverse frame ,oints. #he precast elements are ,oined by welding the pro,ected reinforcement bars >dowels? and casting the concrete in place. ;oints between the cruciform elements
Figure 8: # perspecti.e dra,ing so,ing cruci/or$ and linear units (WHE Report 33& Kyrgyzstan
Figure 6: Hollo,-core precast slab (W HE Report 33& Kyrgyzstan
are located at the mid(span of beams and columns$ whereas the longitudinal precast beam(column connections are located close to the columns.
#hese systems rely on shear walls to sustain lateral load effects$ whereas the slab(column structure resists mainly gravity loads. #here are two main systems in this category2 F F
3ift 3ift(s (sla lab b sy system stem with with wall wallss "res "restr tres esse sed d slab slab(c (col olum umn n syst system em
3ift(slab systems were introduced in the last decade of the -oviet 5nion >period )768()767? )768()767? in some of the -oviet Republics$ including HyrgyDstan$ #ad,iistan$ and the
Caucasian region of Russia$ etc. #his type of precast construction is nown as @-eria H5B. #he load(bearing structure consists consists of precast reinforced concrete columns and slabs$ as shown in 9igure )8. "recast columns are usually two stories high. All precast structural elements are assembled by means of special ,oints. Reinforced concrete slabs are
Figure 14: # li/t-slab building o/ 7'eria 7'eria K59 under construct construction ion (WHE Report 36& Kyrgyzstan Kyrgyzstan
Figure 11: +lan o/ a typic typical al li/t-s li/t-slab lab building (WHE WHE Report Report 36& 7'eria 7'eria K5&9 Kyrgyzstan
poured on the ground in forms$ one on top of the other$ as shown in 9igure )). "recast concrete floor slabs are lifted from the ground up to the final height by lifting cranes. #he slab panels are lifted to the top of the column and then moved downwards to the final position. #emporary supports are used to eep the slabs in the position until the connection with the columns has been achieved. In the connections$ the steel bars >dowels? that pro,ect from the edges of the slabs are welded to the dowels of the ad,acent components and transverse reinforcement bars are installed in place. #he connections are then filled with concrete that is poured at the site. Most buildings of this type have some ind of lateral load(resisting elements$ mainly consistin consisting g of cast(in(p cast(in(place lace or precast precast shear walls$ etc. In case lateral load(resi load(resistin sting g elements >shear walls$ etc.? are not present$ the lateral load path depends on the ability of the slab(column connections to transfer bending moments. &hen the connections have been poorly constructed$ this is not possible$ and the lateral load path may be inco incomp mple lete te.. see >see 9igu 9igure re )/?. )/?. Afte Afterr prestressing$ the gaps between the slabs are filled with in situ concrete and the tendons then become bonded with the spans. -eismic loads are resisted mainly by the shear walls >precast or cast(in(place? positioned between the columns at appropriate locations. #his technology has been used in Kugoslavia during the last *8 years under the proprietary name$ @IM- Building -ystem$ and it ca n be found in all ma,or Kugoslav cities$ including including Belgrade$ Novi -ad$ Nis$ and in other countries$ such as Cuba$ the "hilippines$ and 4gypt. A typical building under construction is shown in 9igure )0.
Figure 1": +ost-tensioned +ost-tensioned slab-colu$n connection connection (WHE Report %8& 'erbia and ontenegro
Figure 13: #sse$bly o/ precast colu$ns in progress (WHE Report %8& 'erbia and ontenegro
#.) EARTHQUA>E PER/ORMANCE
#here #here is a genera generall concer concern n among among the the earth earth!ua !uae e engin engineer eering ing commu communit nity y regarding the seismic performance of precast construction. Based on experience in past earth!uaes in 4astern 4uropean and in Central Asian countries where these systems have been widely used$ it can be concluded that their seismic performance has been fairly satisfactory. Armenia? >M:.? earth!uae is well nown >see 9igure )*?. no damage? of several large(panel buildings under construction at the same site$ as shown in 9igure ) these large(panel buildings were of a similar seria as the large(panel buildings buildings described in the &<4 Report from the Russian 9ederation >-eria *1*?. #he buildings of -eria ))) were similar to the precast concrete frame system of -eria II-$ described in the &<4 report 11 >5Dbeistan?. #he precast prestressed slab(column system >IM- Building -ystem? described in &<4 &<4 Repo Report rt 16 >-er >-erbi biaa and and Mont Monten eneg egro ro?? has has unde underg rgon onee exte extens nsiv ivee laboratory testing that predicted excellent resistance under simulated seismic loading. #hese building have been sub,ected to several moderate earth!uaes without experiencing significant damage. ue to their large wall density and box(lie structure$ large(panel buildings are very very stiff stiff and are charac character teriDe iDed d with with a rather rather small small fundam fundament ental al period period.. 9or
example$ a 7(story building in HaDahstan has a fundamental period of 8.0 to 8.* sec >&<4 Report 0/?. In general$ large(panel buildings performed very well in the past earth!uaes in the former -oviet 5nion$ including the )766 Armenia earth!ua earth!uaee and the)7:1 EaDly earth!ua earth!uaes. es. It should should be noted$ noted$ however$ however$ that large(panel buildings in the area affected by the )7:1 EaDly earth!uaes were not designed with seismic provisions. Most such buildings performed well in the firstearth!uae >M :.8?$ but more damage was observed in the second earth!uae that that occu occurr rred ed the the same same year year >M :.0? :.0?$$ as some some buil buildi ding ngss had had been been alre alread ady y weaened by the firstearth!uae >Russian 9ederation$ &<4 Report ?. 3arge( panel buildings buildings performed well in the )7:: %rancea >Romania? earth!uae >M :./? and in subse!uent earth!uaes in )761 and )778 >Romania$ &<4 Report 60?.
Figure 1*: uilding collapse in te 1688 'pita0 (#r$enia eartua0e (WHE Report %%& 5zbe0istan
igure e Figur
;arg ;argee-pa pane nell concrete buildings re$ain re$ained ed unda$a unda$aged ged in te 1688 'pita0 (#r$enia eart eart ua ua0e 0e (/ar (/ar bac0 bac0& & ,ereas te precast /ra$e buildings su//ered e
2.9 SEISMIC-STRENGTHENING TECHNOLOGIES
1!: 1!:
According to &<4 reports$ no ma,or efforts have been reported regarding seismic strengthening of precast concrete buildings. &<4 Report 11?. #he techni!ues used include the installation installation of steel straps at the column locations >see 9igure )1? and reinforcing the ,oints with steel plates to provide additional lateral confinement of the columns.
Figure 1%: 'eis$ic strengtening o/ precast colu$ns ,it steel straps
According to ;.Maeda did extensive research in evelopment and Application of the -MAR# -ystem and Miyatae$ K. >)770?.L-MAR# >)770?.L-MAR# -ystem2 A 9ull -cale Implementation of Computer Integrated ConstructionL$ #he )8th International International -ymposium on Automation and Robotics in Construction$ May )770.
#.%?.% INTRODUCTION
In ;apan$ in spite of the increased demands of construction construction there are growing shortages in the wor force which is also ageing . -illed craftsmen are particularly in short supply .It has been pointed the first first time. #aing these these results into consideration$ consideration$ the the technology was introduced introduced in a full fledged manner on a pro,ect in the city of Nagoya$ in the fall of )77). #he construction by -MAR# has successfully completed in the fall of )770 >"hoto. )?. In this paper$ the pro,ect in Nagoya is used as an example to explain the basic concept of the system$ technologies applied$ construction procedures used and results for the application. "lans for future development and improvement of the system are also discussed out that the bacground to to this is that that construction operations operations involve involve heavy worloads worloads with much much wor carried out in very a dverse environments . Compensating for this shortage in the wor force and reducing accidents on the wor site $ together with improving productiv improving productivity ity as a means for shortening shortening construction periods $ are some of the serious tass faced by the ;apanese construction industry today. 5nder such circumstances $there has been$ for many years$ a lot of activity in the development of robots and automation for construction wor . &ith this basis of automation technology we see to achieve maximum integration of the various technologies which lead to moderniDation of construction construction i.e. technologies technologies for industrialiDation industrialiDation and systematiDatio s ystematiDation n of the various components of building and computeriDation of site management. -everal ma,or construction construction companies in ;apan have pursued the development of systems based on similar ideas and to date there are a number of proposals . #he -himiDu Manufacturing -ystem by Advanced Robotics #echnology >-MAR#? system of the -himiDu Corporation controls controls all phases of building construction construction from underground wor and superstructure wor to finishing and M4 wor. It also controls various construction construction management tass for the automated construction of high rise buildings. #he formulation formulation of system started in the fall of )778 and the core technology for the system was implemented at an actual construction site for
#.%?.# COMPONENT TECHNOLOGIES O/ SMART SYSTEM
#he -MAR# system secures a safe and comfortable woring environment$ environment$ and also provides a setting for construction which is not affected by wind or rain. 9urthermore$ it aims for a considerable reduction in labour and management man(hour re!uirements$ and shortening of the construction period. In addition$ to respond to the prevailing social demand for protection of the global environment$ a system to reduce waste materials from construction is sought. #his system is applicable for high rise office and hotel buildings which are of steel frame construction construction and involve large amounts of repetitive wors.
#.%?. OUTLINE O/ SYSTEM
In the -MAR# -ystem$ the top floor of the building >9igure )?. )?. Members such as columns$ columns$ beams$ floor floor plans$ and wall panels panels used in the building are hauled continuously continuously using a multiple trolley hoists$ overhead cranes and a special vertical crane. A one touch ,oint system suited to automation automation and mechaniDation is used to connect structural steel members and member ,oints are welded automatically by welding robots. #he roof and outer perimeter parts of the floor under construction are completely covered by protective protective sheets$ and the exterior exterior wall panels for that that whole single floor floor are installed prior prior to ,acing up so that the floor is is unaffected by wind wind or rain. -afety of wor wor is also enhanced enhanced and a comfortable woring environment environment achieved which is unaffected by adverse weather.
#.%?.* LI/T UP SYSTEM
#he lift up system is composed of four ,acing towers which support the entire operating platform and the the lifting mechanisms mechanisms installed at each ,acing ,acing tower.. uring the the assembly operations of a floor$ the tower bases are seated on the steel beams of the building. uring lifting operation$ three hydraulic hydraulic cylinders in each lifting mechanism are operated and the lifting mechanisms are raised by one story height >approximately >approximately *m? to rest on the steel beams of the storey above. Next$ while supporting the operating platform on these steel beams$ the hydraulic cylinders cylinders are again operated and the towers themselves are raised. &hen the towers have risen one story height$ the bases are seated on the structural steel beams of that upper story to complete the lift up operation. 9igure / shows the main components of the lift up system. #he total weight of the entire operating platform lifted up is a pproximately )$/88 tons and the operating time for one storey height is ). hours. #.%?. AUTOMATED CON8EYING SYSTEM
9or conveying the many inds of members$ ten overhead travelling cranes$ five trolley hoists for horiDontal conveying$ conveying$ and a special vertical lifting crane which ascends and descends by wire drive is used instead of the large conventional tower cranes. A trolley hoist lifts up a load from the ground$ rides onto the rails of the above mentioned cranes in succession and reaches its destination$ destination$ all controlled by computer. 3iewise$ the picing up of a load and conveying this to positioning positioning is all done automatically automatically without without manual assistance. assistance. 9igure 0 shows the the components of the automated conveying system. &hen a member is hoisted$ it is conveyed in a continuous continuous operation to reach the destination. #hus$ the assembly of members can be done with less waiting time with an increase in the wor per day. "hotograph / shows a steel column which has been hoisted and$ having reached its destination$ is being installed into place. "hotograph 0 shows the vertical lifting crane located outside of the building. building. A control room is located inside the
#.%?.; AUTOMATED STEEL ASSEMBLING SYSTEM
In order to achieve a smooth setting of a load at a designated place$ the shapes of various ,oints of steel steel struct structure uress had to be modif modified ied.. ;oints ;oints betwee between n steel steel colum column n member memberss and betwee between n column columnss and beams beams were were modif modified ied to inser insertt types types$$ desig designed ned to realiD realiDee free free stand standing ing upon upon inser insertio tion. n. "hotog "hotograp raph h * shows shows a ,oint ,oint betwee between n steel steel column column membe members. rs. #rolle #rolley y hoist hoistss are e!uipped with hoisting ,igs having automatic load releasing functions and which automatically unfasten hoisting wires after assembly of members. In order to assure accuracy of the steel frames when assembling$ an automatic measuring system using laser beams was developed and introduced on this pro,ect. pro,ect. A laser beam produced from a laser emitting apparatus set on the floor is received by a reception device installed at the top of the steel column and the inclination of the steel column from the reference line is detected. #he detected value is digitised$ and the operator on reading the value$ corrects the inclination. #his system is also used for measurements to ascertain the accuracy of a completed floor after completion of welding wors. #.%?.$ AUTOMATED 9ELDING SYSTEM
&elding of column to column and beam to column of structural steel is done automatically using robots. #he composition of the welding system between column and column is shown in 9igure *. #he welding of a ,oint between columns would be horiDontal multi(layered multi(layered three units of newly developed welding robots were introduced on this pro,ect. "hotograph shows a column welding robot in operation. #he robot maes it possible to weld automatically whole groove of a column including corner portions portions in continuity. #he configuration of a ,oint is detected by laser sensor$ and wor is done under optimised welding conditions conditions referring to a data base . #he robot proper is compact compact and light$ weighing weighing )7g$ and handling handling is easy. easy. Because of the high level of automation$ it is possible for a single worer to control / to 0 robots at one time$ and therefore to result in reduction of re!uired manpower. 9our special welding robots for ,oining together columns and beams have been introduced$ introduced$ and welding w elding of beam flanges has been automated.
#.%?.) A!-o6a-e+ Tran1,or-a-ion an+ In1-a55a-ion of Prefa
3arge siDed precast concrete floor plans >fabricated in a "C factory?$ are automatically transported and installed to the designated position$ position$ and the ,oints between two plans are filled up by concrete. "hotograph 1 shows installation of a concrete floor plan. In finishing and e!uipment wors$ beginning with industrialisation industrialisation of interior finish materials$ modularisation of exterior curtain wall panels$ unitisation of e!uipment piping and pipe shafts$ *18 a nd pacaging of e!uipment are aggressively carried out$ and automated transporting transporting and installation are done. "hotograph : shows transportation transportation of an exterior wall panel installed window pane and air conditioning e!uipment.
#.%?.& IN/ORMATION CONTROLLING SYSTEM
9or the purpose of construction management of the entire ,ob site$ a computer integrated management system is introduced. %arious systems such as those for labour safety control$ !uality control$ scheduling$ temporary e!uipment management$ woring drawings preparation$ and overall construction co(ordination are operated through field office. #he production production control system is developed$ which performs inputting construction procedures$ compiling construction construction records$ and monitoring the conditions of apparatus. #he system is connected to the computer for controlling controlling the -MAR# system.
#.%?.%? APPLICATION O/ THE SMART SYSTEM IN CONSTRUCTION CONSTRUCTION O/ THE NAGOYA JURO>U BAN> BUILDING
#he -MAR# system is first applied in construction of the Na goya ;urou Ban building in Nagoya$ ;apan. #he pro,ect pro,ect was started in +ctober )77) and is scheduled scheduled to be completed completed by the end of 9ebruary )77* . #he building will stand 66 meters tall upon completion$ /8 stories above ground and / stories underground . #he total floor area measures /8$888 s!uare meters.
#.%?.%% Con1-r!2-ion Pro2e+!re
#he construction procedure procedure in use of the -MAR# system is shown in 9igure . &hen wor on the substructures has been completed$ the parts for the roof story >
4ffects realised due to use of the -MAR# system which have come to light through its application in the Nagoya pro,ect are as described below2
" I ' I6,ro(e6en- of =orin3 en(iron6en-
#hrough its all(weather protection >&eather "rotection Cover?$ wor can be performed safely and in comfort$ without being affected by the weather. 9or example$ welding can be done in a normal manner even on a rainy day. uring the construction by the -MAR# system$ *1) approximately/8 approximately/8 of the period were rainy or windy days.
&orers have been freed from operations with heavy worloads such as assembling structural steel and welding. Although not completely unmanned wor $human wors can be limited to intelligent wor such as monitoring $ maintenance$ and !uality assurance.
&ith effects of introducing introducing computerised control and robotics$ and also prefabrication and modularisation$ modularisation$ it has been made possible for man(hour re!uirements to be reduced. It is estimated that for this pro,ect including structural $ finishing and e!uipment wors $ a reduction of about 08 in lab or can be achieved. 4specially$ as for wors which are involved in the -MAR# system$ about 8 in lab or were reduced. >9igure 1? "*' Re+!2-ion of =orin3 +a1 for ea24 f5oor
uring the construction$ the number of days re!uired to complete each floor by the -MAR# system is greatly reduced from 7 days to days at the last stage$ due to the improvement of software program$ woring method and practice of worers. It is expected about /8 to *8 reduction of construction construction period for the next application of the system. "' Re+!2-ion of =or5oa+ on 1i-e 6ana3e6en-
#he worload on site management personnel has been greatly lightened through introduction introduction of a ,ob site information information management system system controlled by computer. >1? Reduction Reduction of construction construction wastes It has been made possible possible for construction wastes to be reduced through wide scale adoption of modularisation of materials and prefabrication. prefabrication. Comparing to the conventional site$ about :8 >:88 ton? of wastes were reduced in this pro,ect. 9igure : shows the comparison of the construction wastes.
#.%?.% CONCLUSION
#hrough its application to the Nagoya ;urou Ban building$ an outloo has been gained for realisation of a safe and comfortable wor site unaffected by weather $ reduction in labour and management re!uirements$ elimination of haDardous and heavy worload operations$ and reduction of construction construction wastes. 9or 9 or further improvements in productivity$ productivity$ we must realise more reduction in manpower re!uirements and shortening of construction construction periods $ even greater level of automation$ and more intensification of industrialisation industrialisation such as those in prefabrication$ and constitution constitution of an overall site management system. In the future$ establishment of a building design suited to automated construction construction and realisation of an information system integrating design and construction programs$ construction management$ and construction operations will come to be sought. It is from such a viewpoint that -himiDu Corporation is striving to upgrade the level of the -MAR# system to establish it as a building production production system of a new image advancing toward the /)st century.
CHAPTER 7 RE/ERENCES .% Ar-i25e1 an+ Boo1 •
Amold %an Acer L"recast Concrete( &hat and &hyL$ #he Indian Concrete ;ournal$ "ublished By ACC limited$ %ol(6'ecember /8))
•
-hubhangiBidvwe And -hriyal-ethumadhavanL -hriyal-ethumadhavanL #he
•
International -peas L #all BuildingsL$ Construction &orld. %ol()0'9ebruary /8))
•
CharuBhariL Eaining 9ormL$ Construction &orld. %ol()0'9ebruary /8))
•
&oods ;ohn L Multi 9amilyL$
•
-urlaNipesh L
•
Raymond &ong &ai Man L Application of 9orm &or for
•
efinition of @Mass "roduction in @Industrial 4ngineering and "roduction Management Britannica Macropaedia$ The New Encyclopaedia Britannica$ )th 4dition$ %ol. /)$ p. /8*$ )767.
•
5NI+$ )760. esign and Construction of "refabricated Reinforced Concrete 9rame and -hear(&all Buildings. Building Construction 5nder -eismic Conditions in the Balan Region.%olume /.5N"=5NI+ "ro,ect R4R=:7=8)$ %ienna$ Austria.
•
44RI >)767?. Armenia 4arth!uae Reconnaissance Report. -pecial -upplement to 4arth!uae -pectra$ 4l Cerrito$ California.
•
Hudoh R $ @ Implementation of an Automated Building Construction -ystem -ystem "roc. +f
the )0th International CIB &orld Building Congress$)77.
•
•
•
&aisaa #. @Automatisation of Reinforcement &or in
Hoeehn 4$ @Climatic 4ffects on Construction "roc. A-C4 %ol.)))
Miyatae$ K. >)770?.L-MAR# -ystem2 A 9ull -cale Implementation of Computer Integrated ConstructionL$ #he )8th International -ymposium on Automation and Robotics in Construction$ May )770
.# 9e<5io3ra,4 •
www.iea.org=papers=/881=pwPh www.iea.org=papers=/881=pwPhighrise.pdf ighrise.pdf
•
www.highriseconcrete.com=multifam www.highriseconcrete.com=multifamilyParticle.pdf ilyParticle.pdf
•
www.allindiaarchitects.com=studentP www.allindiaarchitects.com=studentPartical=))1 artical=))1)185rbanism )185rbanismP+ctP81.pdf P+ctP81.pdf
•
http2==civil(resourses.blogspot.com=/8)8=81=formwor.html
•
http2==www.scribd.com=doc=/ http2==www.scribd.com=doc=/:1167= :1167=presentation(do presentation(doa a
•
http2==findarticles.com=parti http2==findarticles.com=particles=miP!ua0: cles=miP!ua0:7=isP/88 7=isP/88/)8=aiPn/) /)8=aiPn/)0/8076=Qtag 0/8076=Qtagcontentcol) contentcol)
•
http2==www.world(housin http2==www.world(housing.net=upload g.net=uploads=concretePshearP s=concretePshearPwall.pdf wall.pdf
•
https2==pdfserve.informaworld.com=*:6/*7P:7060:)*7.pdf
•
http2==www.iit.ac.in=nicee=uucee=arti http2==www.iit.ac.in=nicee=uucee=article=)0P8)8 cle=)0P8)8.pdf .pdf
