Tilt Up Construction

ADOPTION OF TILT UP TECHNOLOGY FOR LOW RISE COMMERCIAL BUILDINGS IN KENYA
BY MAINGI KIRIINYA KEVIN AB243-0192/06
A thesis submitted in partial fulfillment for the award of degree of Bachelor of Construction management in the department of construction of Jomo Kenyatta University of Agriculture and Technology.
AUGUST 2011
DECLARATION.
I declare that, this thesis is my original work and further affirm to the best of my knowledge that this thesis has not been presented in this university or any other institution of higher learning for award of degree or any other purpose.
Signed (Researcher); Date Maingi Kiriinya Kevin
I confirm that the work reported in this thesis was carried out under my supervision. Signed (Supervisor); Date Mr. P.M Gatuhi
Signed (C.O.D); Date Mr. Daniel Saiva
INSPIRATION The mind is its own place, and in itself Can make a heaven of Hell, a hell of Heaven.
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ACKNOWLEDGEMENT My appreciation goes to my supervisor, Mr. P.M Gatuhi, for the very insightful contributions and comments that you offered to make this a reality. May God bless you. To the Jomo Kenyatta University of Agriculture and Technology for providing a learning environment and especially to the department of Construction Management accept my gratitude. To the Chairman Department of Construction Management, Mr. Daniel Saiva, you gave extraordinary support through advice and understanding in every way. You sacrificed so much to get this done. Thank you so much. Those who found time to answer interviews and fill the questionnaires thank you all. God will bless you. Special regard goes to the Tiltup Concrete Association (America) for all the material and educational videos. Thank you. Finally to classmates and friends who have been a source of encouragement and assistance. I will cherish all the moments.
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ABSTRACT Tilt up concrete construction has been identified as a potential solution to improve overall performance of construction industry like labour, quality, cost effectiveness, safety and productivity in form of saving time. This method with extensive pre planning has shown that it can offer effective mode of construction especially for low rise commercial buildings. However since its introduction in the United States America till today, Tilt up technology is not well accepted by the construction parties in Kenya. This study sort to indentify the construction methods used in the country and compare them with tilt up concrete technology. This was done through analysis of the views collected in the field and cost analysis of the building methods.. It is hoped that the findings of this research could assist Kenyan Contractors in making guided decision in order to adopt this form of technology.
TABLE OF CONTENTS
CHAPTER 1 ........................................................................................................................................... 1 1.1 1.2 1.3. 1.4 1.5 1.6 1.7 1.8 1.9 Introduction: ............................................................................................................................ 1 Background to the problem: .................................................................................................... 1 Existing knowledge: ................................................................................................................. 2 Problem Statement: ................................................................................................................. 4 Purpose of the study: ................................................................................................................ 6 Research Justification: .............................................................................................................. 6 Significance of the study: ......................................................................................................... 7 Research Objectives: ................................................................................................................ 8 Organization of the Study: ........................................................................................................ 8
CHAPTER TWO .................................................................................................................................. 10 LITERATURE REVIEW ...................................................................................................................... 10 2.1 2.2 2.2.1 INTRODUCTION: ............................................................................................................... 10 DEFINITION OF TERMS .................................................................................................... 11 Tilt up construction: ....................................................................................................... 11
2.2.2 Shear wall: ............................................................................................................................ 12 2.2.3 Precast panels: ...................................................................................................................... 12 2.2.4 Safety.................................................................................................................................. 13 2.2.5 Quality: ................................................................................................................................. 14 2.3 THE CONCEPT OF TILTUP CONSTRUCTION METHOD ................................................. 14
2.3.1 Types of panels: .................................................................................................................. 14 2.3.2 Feasibility review ................................................................................................................ 15 2.3.3 Tilt-Up Construction Sequence ............................................................................................ 16
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2.4 2.5
Advantages of tilt up an alternative building method .............................................................. 25 PLANNING FOR TILTUP CONSTRUCTION: ..................................................................... 29 The design and construction team: .................................................................................. 29 Optimizing the benefits of tilt-up construction: ............................................................... 30 Layout of panels and erection sequence .......................................................................... 32 Casting position of panels ............................................................................................... 33 Cranage and crane movements ........................................................................................ 38
2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.6
THE FLOOR SLAB AND CASTING SURFACE .................................................................. 39 The Concrete Floor Slab ................................................................................................ 39 Cure Coats and Bond breakers ........................................................................................ 39
2.6.1 2.6.2 2.7
CASE STUDY GATEWAY SHOPPING CENTRE ( SOUTH AFRICA) ............................ 42
RESEARCH METHODOLOGY .......................................................................................................... 46 3.1 Introduction ............................................................................................................................... 46 3.2 Research Design: ................................................................................................................... 46 3.3 Nature and sources of data: ........................................................................................................ 47 3.3.1 Primary data ......................................................................................................................... 48 3.3.2 Secondary data: .................................................................................................................... 48 3.4 Target population and sampling frame........................................................................................ 48 3.4.1 Sample size: ......................................................................................................................... 48 3.4.2 Sampling methods: .............................................................................................................. 49 3.5 Methods of data collection and instruments: ............................................................................... 49 3.5.1 Interview schedules. ........................................................................................................... 49 3.5.2 Photographs. ....................................................................................................................... 49 3.5.3 Questionnaires..................................................................................................................... 49 3.6 Methods of data analysis and presentation: ................................................................................. 50 3.6.1 Pie Charts: ............................................................................................................................ 50 3.6.2 Tables: ................................................................................................................................. 50
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3.6.3 Bar graphs:............................................................................................................................ 51 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.8 Statistical analysis: ............................................................................................................. 51 Mean: ............................................................................................................................. 51 Mode:............................................................................................................................. 51 Range: ............................................................................................................................ 51 Standard deviation: ......................................................................................................... 51 Percentiles: ..................................................................................................................... 52
Comparative techniques: ........................................................................................................ 52 Reliability of data: .......................................................................................................... 52 Validity of data:.............................................................................................................. 52
3.8.1 3.8.2
CHAPTER 4 ......................................................................................................................................... 54 DATA PRESENTATION AND ANALYSIS ........................................................................................ 54 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Introduction ........................................................................................................................... 54 Method of construction .......................................................................................................... 55 Cost overruns ........................................................................................................................ 56 Time overruns ........................................................................................................................ 57 Tilt up construction and its construction: ................................................................................ 59 Comparison matrix between building methods ....................................................................... 60 Tilt up construction in Kenya ................................................................................................. 63 Future of Tilt up concrete in Kenya ........................................................................................ 64 Cost Analysis between Conventional, Precast and Tilt up construction ................................... 65 Conventional analysis ..................................................................................................... 65 Tilt up construction cost analysis: ................................................................................... 70
4.9.1 4.9.3 4.10 4.11
Comparative study between different building methods in Kenya ........................................... 72 Machinery .............................................................................................................................. 73
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4.12
Conclusion ............................................................................................................................. 74
CHAPTER FIVE ................................................................................................................................... 75 SUMMARY, CONCLUSION AND RECOMMENDATION ................................................................ 75 5.1 5.2 Introduction ........................................................................................................................... 75 Findings ................................................................................................................................. 75 Methods of construction used in Kenyas construction industry ...................................... 76 Establish the awareness of tilt up concrete technology in Kenya ...................................... 76 Benefits of tilt up construction over other construction methods ...................................... 77 Construction design and process of building a tilt up building: ........................................ 77 Recommend the suitability of using tilt up construction in the industry ........................... 78
5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.4 5.5
Summary ............................................................................................................................... 78 Recommendations .................................................................................................................. 78 Further areas of research ........................................................................................................ 78
BIBLIOGRAPHY APPENDIX A: PRIMARY DATA COLLECTION METHODS A.1 Sample questionnaire A.2 Sample Interviews Questions
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List of Tables Table. Page Table 4.1 Distribution of the target samples .......................54 Table 4.2 Performance comparison matrix ........61 Table 4.3 Surface area analysis of the faade (conventional method)....66 Table 4.4 Conventional cost analysis..67 Table 4.5 Precast cost analysis...69 Table 4.6 Tilt up cost analysis.71 Table 4.7 Tilt up verses precast comparative study...72 Table 4.8 Tilt up verse conventional masonry....73
List of Charts ChartPage Chart 4.1 Option for tilt up construction...60 Chart 4.2 Adoption of tilt up in Kenya..63
List of Graphs Graph..Page Graph 4.1 Method of construction54 Graph 4.2 Cost overruns...............56 Graph 4.3 Time overruns.....57 Graph 4.4 Performance comparison matrix..61 Graph 4.5 Future of tilt up construction...63
List of Figures Figurepage Figure 2.1 Lifting radius.....35 Figure 2.2 Panel arrangement on floor slab...............36 Figure 2.3 Inserts and fixing source...36 Figure 2.4 Typical panel setting out information..38
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List of Plates Plate.Page Plate 2.1 Casting slab.17 Plate 2.2 Drawing guide lines17 Plate 2.3 Placing brackets..18 Plate 2.4 Dimensioning..18 Plate 2.5 Edge of formwork...19 Plate 2.6 Complete surface19 Plate 2.7 Rebar placement.19 Plate 2.8 Rebar at openings..19 Plate 2.9 Embeds and inserts20 Plate 2.10 Ready of casting...20 Plate 2.11 Concreting21 Plate 2.12 Trowelling.....21 Plate 2.13 Power floating......22 Plate 2.14 Completion...22 Plate 2.15 Cured panels....23 Plate 2.16 Drilling for brackets....23 xii
Plate 2.17 Bracing and Props......24 Plate 2.18 Lifting.24 Plate 2.19 Guiding the panels..........25 Plate 2.20 Bracing of props.................25 Plate 2.21 A complete tilt up building with curves.........45 Plate 4.1 Two storey conventional masonry faade..65 Plate 4.2 Two storey precast faade...68 Plate 4.3 Two storey tilt up construction faade70
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CHAPTER 1 1.1 Introduction:
The construction industry is one of the worlds major industries. Its achievement in rebuilding areas devastated by both natural and man-made disasters, and in providing power, services and communications to meet the rising needs and expectations of people throughout the world, has conferred great benefits on the human race. Despite mechanization, technology and an attempt to implement Total quality management, construction projects in Kenya remains costly and behind schedule. With a significant boom in the construction industry and a gradual growing awareness of the need for rapid construction and cost reduction in building the country needs to look at alternative technology to offer not just a safer, cost efficient technology but a technology that will guard the environment and reduce the negative impact that result from over exploitation of sources of building materials used in the convectional ways of building. 1.2 Background to the problem:
Over the years research has striven to promote and advocate comprehensive technologies in buildings. However individual construction contractors unaware of the benefits derived from these technologies do not echo and support the research effort. Speed of putting up structures is a major consideration in most building projects. Use of traditional system of building methods, such as block and mortar has always resulted in late completion of projects. For a building method to be chosen in the highly competitive construction market it has to show that its benefits outweigh those of the alternatives and can have the ability to provide effective quality control systems. Quality can be defined as the continuous incorporation of the users 1
demand into the production of the product. Regrettably, traditional methods have not lent themselves to this definition. The situation with regard to construction technology used in Kenya is still lamentable and there is much room for improvement and breakthrough. 1.3. Existing knowledge:
Tilt-up construction was first introduced in the early 1900s in the USA. However it was not until the 1950s with the introduction of mobile cranes and ready-mixed concrete that its use really grew. At this time the first design and construction guides appeared in the USA, paving the way for pioneering contractors to capitalise on the increased sophistication of the technique in the following decades. From the late 1970s to the present day, tilt-ups use has grown substantially, due partly to traditional skills shortages but mainly to its speed, providing more efficient construction to respond to growing economic pressures, and an increase in the real and perceived quality of tilt-up buildings . Its established use has spread from the USA market, to those of Australia and New Zealand. In each case, its development followed a distinct pattern. The technique began in low-rise industrial structures where it developed a quality image. Whilst increasing its share of the market in these building types, it diversified into other commercial, leisure and residential sectors. The technology, expertise, and reliability of tilt-up has improved due to improved structural engineering, availability of products specifically developed to suit tiltup, achievement of better quality finishes, and changes in procurement routes. Currently, in the USA, some 13 million square metres of tilt-up walls are built each year, the equivalent of around 7000 low-rise buildings. This increased at a rate of 12% between 1995 and 1996. Of these buildings, around 65% are industrial or warehousing, 25% are offices, and 10% are retail development and other miscellaneous projects. In Australia, tilt-ups use for the industrial market took off in the 1970s because of a dramatic rise in brick prices, and a crisis of confidence in low2
rise metal-clad structures, often referred to as sheds . Subsequently, it has also become popular for speculative house building in the 1990s where it has now been used for terraced houses, luxury apartments, individual villas and housing association developments. Canada has an established tilt-up market and the method has also been used in other countries such as Malaysia, Argentina, Brazil, Hungary, Mexico and South Africa. In the UK and Ireland, tilt-up has been mainly used for industrial and warehousing structures, some incorporating office space. It is interesting that these tilt-up structures remain quite distinct, standing out from often very commonplace metal-clad 'sheds'. In addition to advanced factory buildings in Scotland, further buildings have been constructed by the Watchtower organisation in London and in Co.Wicklow, Ireland. The latter particularly have achieved exceptional quality and appearance. The Watchtower organisation is highly committed to tilt up and has a rolling program of around 40 new buildings under construction, throughout the world, utilising tilt-up. Recently a contractor specialising in design-build cold store projects in the UK has adopted tilt-up for its plant rooms in order to save time and reduce construction problems. There is a growing trend worldwide towards the use of tilt-up concrete sandwich panels. One supplier is now claiming that about 5 million square metres of panels have been built using its system alone. Tilt-up concrete construction is used throughout the world for a diverse range of building types. It is a site-based method of casting large concrete panels on the ground slab, and then tilting them into place, usually to form walls. Tilt-up is said to offer a fast, cost-effective building with long-term performance advantages and scope for architectural expression. However, criticisms of the technique are that it involves a significant amount of pre-planning, and involves fully exposed concrete finishes, which can be challenging for the designer and contractor (Glass, 1998; MacCraith, 1996). To date, tilt-up concrete has been used only rarely in the Kenya, so 3
there is scope to investigate why such innovation is not more widely used. Recent comments from within the Kenya construction industry suggest its willingness to adopt any new innovation is in question. Some believe the industry is fundamentally conservative, and requires significant advantages to be shown before it accepts new ideas, others maintain it is a successful industry, introducing innovation despite difficulties of minimal R&D spend and little replication (MacLeod, Kumar, & McCullough, 1998). Based on research carried out by Africas construction industry professionals, there are suggestions that industrialized based systems such as tilt up have been hampered by a Cost-Focused Decision System in Africa, which effectively impedes innovation by considering only initial costs of setting up such a system. In other construction cultures particularly in the United States, more accustomed to a Value-Focused Decision System, tilt-up and other innovative techniques are more readily accepted arguably because life-cycle and investment costs are also considered. Therefore this research is timely, in that it addresses the wider issue of the Kenyas willingness to adopt innovation. 1.4 Problem Statement:
The construction industry is one of the most dynamic, risky, challenging and rewarding fields. It involves numerous uncertainties and it is widely associated with a high degree of risk due to the nature of construction business activities, processes, environment and organization. Complexities of the project, location, type of contract, familiarity with the work and breakdown in communication are some of the significant contributors to risks in construction industry. Risk has been defined in various ways:i) Risk can be expressed as an exposure to economic loss or gain arising from involvement in the construction process. Some researchers describe risk in relation to construction 4
project whose variation results in uncertainty in the final cost, duration and quality of the project. ii) Risk can also been defined as the probability of occurrence of some uncertain, unpredictable and even undesirable event(s) that would change the prospects for the profitability on a given investment such as construction. Failure to adequately deal with uncertain, unpredictable and undesirable event has been shown to cause serious effects of risk that can be summarized as:a) Failure to keep within cost estimate. b) Failure to achieve the required completion date. c) Failure to achieve the required quality and operational requirements. Tilt up construction is an industrialised building system where the walls are created by assembling forms and pouring large slabs of concrete called panels directly at the job site. The concrete panels are then tilted up into position around the building's slab to form the walls. Because the concrete tilt wall forms are assembled and poured directly at the job site, no transportation of panels is required. One major benefit of this is that the size of the panels is limited only by the needs of the building and the strength of the concrete panels themselves. Tilt-up construction panels can sometimes be extremely wide and/or tall. Tilt-up concrete panels have been measured at just over 21 metres across and almost 28 metres from top to bottom. Thus, architects, Engineers and tilt-up concrete contractors have a great deal of flexibility in planning and creating their building. Its industrialization essentially as an orgaanisational process implies a steady flow of demand; a high degree of organization of work; mechanization to replace human labour wherever possible; research and organized experimentation integrated with 5
production. It can speed up construction process and with less labour on site and, if possible, at less cost and minimized effects of risk. With these advantages, a lot of countries have chosen to use the tilt up walls in their construction industries; especially in the United States of America, Singapore, China and Australia. Tilt up construction is gearing towards providing challenges and fulfilling demands that give satisfaction for development. Developed economies support the use of this technology in order to increase productivity, quality, and reduce time, cost while increasing safety in their construction industries. Due to growing economic pressure for the country, contractors need to rethink and introduce new innovations in construction of commercial buildings such as go downs and office blocks by reducing cost and increasing the speed of construction to match the current economic pressure in the country in order to achieve vision 2030. 1.5 Purpose of the study:
The purpose of the study is to investigate the adoption of tilt up construction in commercial buildings in Kenya. 1.6 Research Justification:
For a building method to be chosen in the highly competitive construction market it has to show that its benefits outweigh those of the alternatives. As tiltup is so widely used for many different building types it clearly has significant benefits to offer. The researcher seeks to establish the benefits that this emerging technology has to offer to the construction industry of Kenya. Safe structures for usage and safety for workers during construction remain a core concern for any 6
building. This thesis seeks to find out how safe are tilt up panels and the amount of load that can be carried by the tiltup panels. The Kenyan construction Industry is characterized by lack of innovation in building technologies. Continued use of conventional building methods and unwillingness of contractors to embrace new emerging technologies has always resulted to inferior finished structures, resulting in time and cost overruns of the finished product. For a building method to be chosen in the highly competitive construction market it has to show that its benefits outweighs those of the alternatives. Research has shown that tilt up is so widely used for many different building types it clearly has significant benefits to offer compared to other methods of construction.
1.7
Significance of the study:
The findings of this study will provide the building will provide the industry with an alternative building method that will enhance efficiency in project delivery. The souring demand for commercial buildings in the countrys growing economy calls for faster, economical and structurally sound buildings at the same time putting consideration of the quality of the end product. Traditional ways of putting up structures have not only resulted to overruns in both time and cost of a project but have also continued to deprive off the country natural resources in form of materials. In a global world that is turning green; we should not wait till its too late to adopt emerging new technologies like tilt up technology. 7
1.8
Research Objectives:
The following are a list of the objectives: i) To find out different methods of construction used in Kenyas construction industry. ii) Establish the awareness of tiltup construction in the industry. iii) To find out the benefits of tilt up construction over other building methods iv) To study the construction design and process of a tiltup wall building. v) To recommend the suitability of using tilt up construction in Kenyas construction industry 1.9 Organization of the Study:
The study begins with chapter one which is introducing the underlying problems facing the construction industry in regard to low rise commercial buildings in Kenya. It sets the objectives of the study, significance and justification of the study. Chapter two outlines in detail about the tilt up construction as an alternative construction method for low rise commercial buildings in the country. This chapter covers the entire process of planning for a tilt up job. Chapter three is the research methodology adopted by the researcher. It outlines the research design adopted by the researcher in his study, source of data, sampling techniques, data collection methods, instruments used and variables measured. It also describes the tools that the researcher opts to present and analyze his data.
Chapter four deals with analysis and discussion of data. This involved the use of field study data, cost analysis of different building methods and comparative study between these methods. This was aimed at finding out the benefits that the new technology has to offer. Chapter five summarizes the entire study. It seeks to show how the objectives set out in chapter 1 of the study have been met. It further recommends on what should be done to implement new innovative technologies that are value engineered. It completes the study by suggesting areas of further study.
CHAPTER TWO LITERATURE REVIEW 2.1 INTRODUCTION:
In this globalisation era, it is essential that for the construction industries to involve parties to be equipped with relevant technology and experience to cope up with the growing economic pressure. This literature review seeks to review the basic methods used in the current day running of the construction industry in relation to safety, speed, quality and cost with the view of comparing it with this unexplored technology in the construction of commercial buildings in Kenya. The construction industry is very labour intensive although it is very competitive. It results in a very low productivity as compared with other sectors. According to Lim Wai Shien 2006 The ineffectiveness and low productivity are caused by failure of the industry to utilize the new as well as other relevant labour reducing technologies. This literature review seeks to answer the following questions: What is Tiltup Construction? What is the difference between Tiltup construction and prefabricated concrete panels? What are the design considerations for a load bearing tilt up panel? How does a company plan for a tilt up project?
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What is the cost involved in tiltup technology way of construction as compared to other traditional methods? What are the challenges that impede adoption of tiltup construction as a way of building in Kenya? How is tiltup construction as a method organized from inception to completion of a project? Can quality be controlled in the tiltup construction method? What are the benefits of using tiltup construction over other similar construction methods? 2.2 DEFINITION OF TERMS
2.2.1 Tilt up construction: Tilt-up construction involves site casting the concrete walls of a building on its floor slab or on a separate casting bed and then tilting and lifting them into position by crane. The result is rapid construction arising from a well-planned process more akin to a factory production line but retaining the flexibility of in-situ concrete work. Tilt-up is a construction method that allows great design flexibility and encourages innovation. Walls can be produced as solid panels for use with added insulation or as sandwich panels where insulation is installed during production. The use of concrete offers the designer structural capacity, fire resistance, sound insulation, thermal capacity, aesthetic qualities and durability. Tilt-up panels commonly carry the roof load and provide transverse load resistance in shear, and thus may be used for both load bearing and non-load bearing walls to a variety of structures.
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Tilt-up received its name from the method of constructing the vertical surfaces. Initially, concrete panels are formed horizontally and set (tilt-up) into their final position. The major cost savings comes from using concrete slabs as casting surfaces, reducing the need for extensive formwork. This method of construction has been utilized for over 50 years in the United States and is commonly found throughout the world. Tilt-up construction is primarily used in low rise structures but is not limited to only single story buildings. Buildings range in size from 500 metres squared homes to over 150,000 metres squared warehouses and distribution facilities. Tilt-up construction is limited only by the equipment placing the panels. 2.2.2 Shear wall: This is a wall that is designed to carry the lateral and vertical loads of a building. The tilt-up panels are used to carry vertical and lateral loads applied to the face of the panels and also to provide shear walls for building stability. The combined stiffness of these walls is usually far greater than is needed to provide stability and only some of the panels are used to carry the wind forces. 2.2.3 Precast panels: This are panels that are prefabricated on a manufacturing plant and transported at site for assembling and fixing to form a building structure. Basically the difference between precast factory panels and tiltup panels is that the factory cast panels must be transported from the factory to the site. Precast panels also offer the following challenges: a) Road transportation limits overall sizes to around 12 m long by 3 to 4 m wide (depending on whether delivered flat or upright on the lorry). There is, therefore, a maximum width of opening that can be incorporated into a single panel.
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b) Different economics may apply, as many units will be cast from a single mould, justifying more complex shapes and costly form liners. c) Transportation and handling may require extra reinforcement and lifting fittings. d) Construction programs alter as casting is independent of ground slabs, but lead times will be longer. It should however be noted that factory precast may be more appropriate where there are special demands on tolerances, finishes, quality or concrete mix (such as coloured concrete or special aggregates).
2.2.4 Safety Safety must be considered in two ways: Safety of structure during construction of building;
With a tilt-up building, much of the work is on the ground; there is no vertical formwork, no scaffolding, and since the floor slab is poured first, workers have a safer working surface. The short and uncomplicated project cycle presents less opportunity for accidents. Safety of the structure during usage;
The design of panels and stability of tilt-up buildings is well tested since their reliability has been proved in the earthquake regions of the world. Tilt-up design recommendations are fully developed in those countries where it is widely used, with many having specific national codes and standards, and other design guides. There are no specific Kenyan tilt-up codes or standards.
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This Thesis will offer design suggestions compatible with the main British structural code for concrete, BS 8110, and contains further references on design to be used by structural Engineers. 2.2.5 Quality: According to K.C. Jain, 1985, quality means fitness for use. Quality means that the product should be fit for use and it is the user who feels that the product is fit to be used. The quality of a constructed building is a measure of how completed building is capable of satisfying the needs of the end user. In this research the definition of quality is divided into two: Quality is the physical outlook and functionality of a building with regard to aesthetics of its facade, finishes, functionality and durability. It is the quality of the building structures defined by local building standards and by the standards codes of practice of the respective building trades involved. Quality is also defined as the quality of the construction site during the construction process. This means technical matters such as how organized site work is. Quality is also the social acceptability of the building product as defined by those living in it i.e. how fulfilled the end users are with the finished building product.
2.3
THE CONCEPT OF TILTUP CONSTRUCTION METHOD
2.3.1 Types of panels: Basically there are two types of panels used in tiltup construction: Non-insulated Non-insulated panels are standard reinforced concrete panels. These panels are efficient and can be used under various loading conditions. Typically, non-insulated panels are used as retaining 14
walls, barriers, and general enclosures that would hide items such as dumpsters and generators. These panels vary in size from 100mm upwards of 250mm depending on their intended use. Insulated Insulated panels are primarily used in colder climates or in cold storage facilities where heating or cooling costs are substantial. There are several ways of achieving an insulated tilt-up panel. One of the easiest ways to insulate the panels is to apply a rigid insulation or to install a furring system with batt insulation. Another method of creating insulated panels is to embed the insulation within the panel. Sandwich panels consist of two layers of concrete separated by a typical 50mm layer of rigid insulation. These sandwich panels take advantage of the insulation while providing the durability of a standard tilt-up panel. As a load bearing panel the typical panel is comprised of an exterior wythe of concrete approximately 35mm to 50mm. The interior wythe of concrete varies from 100mm up to 300mm depending on the load requirements and is tied to the exterior wythe of concrete. 2.3.2 Feasibility review Determining the feasibility is the first step in planning a tilt-up building. Ideally, the perfect tiltup building would be a large warehouse with basic highly repeatable walls where there would be ample room to form and cast the panels. Additionally, there should be enough room for the delivery, movement, and storage of materials. The list below illustrates some of the key questions that need to be analyzed prior to choosing tilt-up construction. Are the exterior surfaces essentially flat? Do they make up at least 50% of the total wall surface?
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Will most of the wall panels rest on the foundation as opposed to elevated lintel panels? Will most of the wall panels overall height be less than 30 feet? Can there be highly repeatable panels, in order to improve the efficiency of panel erection?
Is there enough floor area available to provide a casting surface for the panels? Can the walls be divided into panels whose weight does not exceed the crane capacity?
The above questions are designed to help identify if tilt-up is the right type of construction for the building. The feasibility questionnaire can be filled out for the construction and the results determine whether the building is capable of utilizing the benefits of tilt-up construction even though the typical height of the wall panels will be over 30 feet. 2.3.3 Tilt-Up Construction Sequence The construction sequence for a tilt-up building is slightly different from the construction schedule of a metal wall system. One of the major differences is the sequence of activities for the erection of the roof and walls. The typical sequence of activities for constructing a tilt-up system is as follows: i) First Step - Preparing the Tilt-up Concrete Panel Forms. ii) Second Step - Pouring the Tilt-up Construction Concrete Panels. iii) Third Step - Tilting the Concrete Panels into Place - Tilt-up Construction!
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2.3.3.1 1)
First Step - Preparing the Tilt-up Concrete Panel Forms. 2) Plate 2.2 drawing guide lines
Plate 2.1 Casting slab
Source; Tiltup Concrete Association, (2011)
Prior to the tilt-up construction process beginning, the concrete slab is poured to create the floor, where the tilt-up panels will be created. Skilled labour is necessary at this stage since any defect in casting of the slab will be reflected in the entire panel of the building. The slab should be cleaned thoroughly and any defect in the slab rectified before the application of the bond breaker.
The first step in creating the tilt-up panels is to draw lines on the concrete floor slab where the concrete panels will be formed and poured. The building surveyor should use necessary equipments to enable him to get dimensions in accuracy. This will avoid any inconsistencies during the assembly of the panels at joints.
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3) Plate 2.3 Placing brackets
4) Plate 2.4 - Dimensioning
Source; Tiltup Concrete Association, (2011) Once the lines have been drawn, workers place brackets to outline where the tilt-up panels' outside boundaries, windows and door openings will be.
Source; Tiltup Concrete Association, (2011) The tilt-up concrete panels must be sized and positioned in precisely the right dimensions and location.
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5) Plate 2.5 Edge formwork
6) Plate 2.6 Complete surface
Workers build the tilt-up panel forms out of wood Once assembled, the tilt-up construction panel connected to the braces. 7) Plate 2.7 Rebar placement forms create a pattern on the floor slab. 8) Plate 2.8 Rebar at Openings
Source; Tiltup Concrete Association, (2011) Rebar is placed in the completed concrete panel
Source; Tiltup Concrete Association, (2011) Rebar is placed in the completed concrete panel
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forms. Rebar is a critical component of tilt-up construction. The rebar strengthens the tilt-up concrete panels, making them safer to lift into a standing position and more durable once in place.
forms. Rebar is a critical component of tilt-up construction. The rebar strengthens the tilt-up concrete panels, making them safer to lift into a standing position.
9) Plate 2.9 Embeds and inserts
10) Plate 2.10 Ready for Casting
Source; Tiltup Concrete Association, (2011) Workers also position embeds and inserts into the tilt-up panels so they will become part of the tiltup concrete panels once the pouring takes place.
Source; Tiltup Concrete Association, (2011) With the wood forms securely constructed and the rebar and embeds / inserts in place, the tilt-up concrete panels in the photo above are ready to be poured with concrete.
2.3.3.2 Second Step - Pouring the Tilt-up Construction Concrete Panels. The second step then involves the actual forming of the concrete on the formed panels. Tilt up construction involves casting concrete elements on a previously cast concrete slab. The success of the technique depends very largely on being able to lift one hardened concrete element off 20
another without damaging either of them. To achieve this clean separation, a bond-breaker is required. A bond-breaker is a chemical compound that is applied to the hardened casting surface before placing the fresh concrete for a tilt-up panel. The compound is designed to prevent the fresh concrete from sticking to the hardened concrete and it must be chosen with care and applied correctly to achieve a successful panel lift. The following sequence illustrates the procedure of forming the panels using ready mixed concrete.
1) Plate 2.11 - Concreting
2) Plate 2.12 Troweling
Source; Tiltup Concrete Association, (2011) To create each panel, workers pour the concrete into the forms in a manner very similar to the way floor slabs are poured.
Source; Tiltup Concrete Association, (2011) Once the concrete has been poured, workers trowel the panels for a smooth, consistent finish.
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3) Plate 2.13 - Power floating
4) Plate 2.14 - Completion
Source; Tiltup Concrete Association, (2011) Workers use a variety of equipment, including power trowels, to make sure the panels are level and smooth. These concrete panels will become the exterior (and sometimes interior) walls of the building, necessitating a consistent smoothness or texture on all the panels. Counter checking of the levels is necessary at this stage and if any inconsistency is noted, rework should be done with an approval from the engineer involved.
Source; Tiltup Concrete Association, (2011) The process for building the forms and pouring the concrete tilt-up panels goes quickly. An experienced crew can take a large project from bare slab to completed tilt-up panels in a matter of two weeks. During this stage a suitable curing compound is applied on the floor slab to prevent premature cracks in the panels. If any cracks appear in the panel they should be smoothened off immediately.
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5) Plate 2.15 Cured panels
6) Plate 2.16 Drilling for brackets
Source; Tiltup Concrete Association, (2011) Once the concrete has cured, workers remove the
Source; Tiltup Concrete Association, (2011) Workers do last minute detail work on the tilt-up
wood forms and brackets to leave the tilt-up panels construction panels, including drilling places for lined up on the floor slab. the brackets to be connected.
2.3.3.3 Third Step - Tilting the Concrete Panels into Place - Tilt-up Construction! This is the most exciting event in a tilt up construction. It should be done with a lot of care to ensure that the process is successful. It undergoes various phases that are outlined below.
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1) Plate 2.17 Bracings and Props
2) Plate 2.18 - Lifting
Source; Tiltup Concrete Association, (2011) Tilt-up panels can be massive; this concrete panel weighs about 25 tons. The largest concrete panel used for a tilt-up construction project weighed six times as much, over 150 tons. Panels vary in sizes reaching to a maximum height of 27 meters and as wide as 15 meters. It should however be noted that such large panels require outrigger cranes that have a capacity of over 200 tonnes.
Source; Tiltup Concrete Association, (2011) The mobile crane lifts the tilt-up panel and tilts it into position over the footing. The panels already in place give evidence to just how fast the process for putting up tilt-up panels goes. Careful planning for panels is essential for any tilt up project. Stack casting is also common especially in confined sites. This however calls for an organized structure to enable indentify the panels easily and therefore limit cranage movement around the entire slab.
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3) Plate 2.19 Guiding the panel
4) Plate 2.20 Bracing of props
Workers help to guide a large mobile crane as it lifts a tilt-up concrete panel into place.
Once the concrete panel is set in place, the crew attaches the braces to the slab to keep the panel standing until it is attached to the other tilt-up panels and the roofing system.
2.4
Advantages of tilt up an alternative building method
For a building method to be selected for a project; it has to show numerous advantages over the other alternatives. The benefits of tilt up can be classified into two categories: a) During the construction phase:i) Economy in construction - Extensive cost modeling has shown tilt-up to be highly competitive with traditional construction over a wide range of building
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types and sizes. The labor team that is used in tilt up construction is smaller than the team in the conventional methods of building. ii) Speed of construction - This is often a major reason for choosing tilt-up. Tilt-up construction offers several opportunities to "compress" the schedule and deliver the building very quickly. After the floor slab is placed, the typical elapsed time from starting to form the panels until the building shell is completed may be only four to five weeks. Materials for wall panels are easily procured with minimal lead times, allowing a fast start to a near-factory assembly line process, which progresses while any roof steel is fabricated. iii) Ease of construction - The uncomplicated construction method simplifies and minimizes on site work and reduces labour costs. iv) Safety - Tilt-up concrete is a proven, safe method of construction. The vast majority of the project takes place on the ground rather than on scaffolding, reducing many of these risks normally faced by workers. v) Aesthetics - Tilt-up concrete buildings are not prefabricated. Each one is customdesigned for the client's needs and preferences. A full range of building finishes, wall textures and adornments, colors, even curved walls, are available with this method. Tilt-up construction provides architects and designers with virtually unlimited flexibility in crafting a building that is functional, durable and aesthetically pleasing. b) During the life-time and usage of property:i) Durability - Tilt-up concrete buildings are extremely durable. Many structures created in the 1940s are still in operation today, with little apparent wear. A
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testament to the strength of tilt-up construction, general contractors in earthquakeprone California now use this method for 90% of their one-story industrial building projects. ii) Fire Safety - The concrete used in tilt-up panels meets the fire-resistance standards of even the most demanding building codes. For example, a 6.5" concrete wall offers a fire resistance rating of four hours or more. Tilt-up panels are also frequently used in the building's interior as fire walls. Tilt-up buildings offer real protection and safety for their tenants' employees, property and ongoing operations. iii) Ease of Maintenance - Tilt-up construction buildings require little in the way of ongoing maintenance, outside of periodic cleaning and repainting as desired. Concrete is impervious to insect or rodent infestation, so this problem becomes a relative non-issue as well. iv) Repairs and Expandability - In the event a wall is damaged by a forklift or truck, damages are typically more localized on a panel than in other types of structures, like steel buildings. Also, the modular design of the panels allows for easier repairs and expansion of the building. v) Security - Facilities that require positive security and management of the interior environment - prisons, classified manufacturing facilities, businesses with clean rooms - will appreciate the strength and control afforded by concrete and tilt-up buildings. vi) Reduced Insurance Premiums - Because tilt-up concrete buildings have superior fire resistance ratings and have been proven to withstand severe weather
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and earthquakes, these cement buildings typically enjoy better insurance rates than steel buildings or other types of structures. vii) Reduced Operating Costs - Concrete provides excellent insulation, reducing the ongoing heating and cooling costs for the tenant. This insulation extends to sound as well as temperature. Workers in a tilt-up office building located in a noisy area will be less affected by the environment. By the same token, a manufacturing business that generates noise will have less effect on its neighbors and will find it easier to comply with local noise ordinances.
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2.5
PLANNING FOR TILTUP CONSTRUCTION:
The planning process is the most important to the effective design and construction of tilt-up structures. There is need for effective communications between the design and construction functions. Casting layout and erection sequence, cranage, panel sizes and tolerances, and types of panel joints must be pre-planned prior to the erection of these massive panels if the project is to succeed without requiring rework of the panels.
2.5.3 The design and construction team: The simplicity of tilt-up results from careful planning for its construction during design. If the benefits and versatility of tilt-up are to be fully exploited and its speed and cost fully maximized every design and construction team have to be involved (M.F Southcott and Alan Tovey, 1998). The teams of a tilt up project usually consist of the following: i) The Architect- Responsible for the design of the building and its aesthetics. ii) Panel designers- They are usually Structural engineers who design the panels to be structurally sound and ideal for lifting conditions. iii) Contractor- This is usually the company that is subcontracted to do the casting of the panels. iv) The Lifting contractor- This is the contractor who is tasked with the critical task of lifting the panels into place to form walls of buildings. The lifting contractor usually recommends the best lifting accessories to be embedded in the panels.
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The operation of lifting is critical to any successful lifting job and the lifting contractor should be consulted as early as possible in the planning process (M.F Southcott and Alan Tovey, 1998). It is important that each member of the team is aware of the constraints of the tilt-up method and of the broad implications of any planning decision. Compromise will often be necessary; the participation of all members of the team in the decision-making process is therefore required if the best solution is to be found, particularly for the casting and erection sequences. Circumstances such as project location or tendering procedures may dictate that the full team is not known at the design stage. In such cases, the designer should make every effort to compensate for missing input by soliciting advice from specialists with local knowledge (M.F Southcott and Alan Tovey, 1998). These could include equipment suppliers, crane operators and specialist sub-contractors. Changes made during construction must be very carefully considered, since many decisions depend on or affect other operations. As with other forms of construction, reversing one decision may start a chain reaction that could necessitate the reconsideration of all subsequent decisions. Tilt-up is ideally suited to design and build contracts (M.F Southcott and Alan Tovey, 1998). However, other forms of procurement are successfully employed. In all cases it is important that the ground slabs (and ideally the foundations) are constructed by the same contractor as the tiltup panels to avoid problems with finish and tolerance. In this way, tilt-up reduces the number of trade packages and interfaces, resulting in reduced risk of conflict and in increased efficiency. 2.5.4 Optimizing the benefits of tilt-up construction: The most favorable application for tilt-up is a large low-rise modest building with few openings, allowing a near production-line process of forming and erecting almost identical panels. 30
Constructions such as warehouses, distribution centres and some industrial and retail buildings can come close to this ideal. However, many other buildings are also suitable and the following checklists may be used to help identify them (M.F Southcott and Alan Tovey, 1998). i) Wall to floor ratio - Ideally this should not exceed 70 to 80% to allow walls to be cast individually on the floor, with space for the crane to operate. However, stack-casting of some panels or the use of adjacent temporary casting beds is not uncommon, permitting a higher ratio, or even removing the need to use the ground slab. When the slab is used for the construction of the panels it must be designed for both in-service loads and for any cranage loads during erection. ii) Configuration Construction efficiency will be maximised by a building largely composed of walls that permit a large number of similar sized wall elements, but more variable building forms are also viable. iii) Panel size - A typical site-cast panel for a low-rise building can be around 7.5 to 9.0 m high and 7.5 m wide and weigh between 25 to 35 tonnes. However, between 15 and 25 tonnes is a more typical weight for a tilt-up panel in order to make optimum use of cranage. Economic construction of buildings of three or more stories is not uncommon. However, these may require a more sophisticated arrangement of lifting rigging than for panels under around 9 m in height, in order to keep lifting tensile stresses and thus thickness low. Equally, weight for cranage can be a restriction. Depending on panel and crane layout, 35 tonnes is a sensible maximum but this is often exceeded. In the USA, panels up to 28 m high and up to 130 tonnes in weight have been successfully lifted, using strong backs and highly specialized equipment (M.F Southcott and Alan Tovey, 1998). 31
iv) Building size - Large buildings conforming to the other criteria in this list particularly favour tilt-up, as expensive crane hire and other fixed costs are absorbed by the increased areas involved, and tilt ups speed advantage becomes most pronounced. Additionally, on the largest projects, careful planning can enable activities to be overlapped, with roof steel erection concurrent with panel lifting and even casting elsewhere.
2.5.5 Layout of panels and erection sequence To optimise crane capacity and usage, wall panels are usually cast face down on the floor slab, as close as possible to their final erected position. Their tops will generally be close to the perimeter slab make-up strip with sides touching neighbouring panels. This allows the crane driver to have full sight of the lifting rigging whilst proceeding down the line of panels. It is essential, therefore, that the layout and casting order should be planned around the proposed erection procedure with access for concreting and finishing in a production-line process. Occasionally the lifting position is different, resulting in reverse pick or blind lifting and increased crane capacity for the longer reach required, e.g. from a set-up outside the slab (M.F Southcott and Alan Tovey, 1998). Panels are normally cast face-down to allow easy lifting, with inserts hidden from sight on the inside face. Additionally, casting with the face down allows easy formation of an architectural finish on the outer face, using form-liners or feature strips placed on the floor slab (M.F Southcott and Alan Tovey, 1998).
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2.5.6 Casting position of panels When there is sufficient area on the slab to cast the panels, the panels can be cast individually without stack casting them on top of the each other. Panel location is best decided by trial and error using a physical model of the building and the wall panels (M.F Southcott and Alan Tovey, 1998). This might take the form of a plan of the ground floor slab, including movement joints, column box-outs, perimeter make-up strip and any other features affecting the slab surface forming the casting bed. Wall panels can be formed to scale in card or even thin plywood and marked up with all features and inserts relevant to the casting and erection procedure (M.F Southcott and Alan Tovey, 1998). Panel sizes and weight, crane capacity and reach, wall and slab configuration, and wall features such as openings, are all inter-related. Panel size is often determined by the availability and cost of cranage (M.F Southcott and Alan Tovey, 1998). Thickness and height are the next most important parameters, which affect both in-service and lifting design as well as cranage. Panel width should also co-ordinate with doors and architectural features and with pad foundations, when used. A decision must be taken early in the design process, taking into account the above factors, and optimising the crane size and number of crane set-up positions. It should however be noted that some buildings, otherwise suitable for tilt-up, may have a wall to floor area greater than the economic maximum of 70 to 80%. According to M.F Southcott and Alan Tovey (1998), to overcome the challenges of casting the panels in such a building, the following should be done: Stack-casting up to six panels releases space for crane access. The upper faces of boxouts for openings are often set low to contain a thin sacrificial layer of concrete. This
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facilitates float finishing of the whole surface giving a good finish for forming the next layer. Careful planning and execution is necessary to maintain tolerances and finishes. Temporary casting beds, typically of 75 mm concrete, can be used outside the building footprint. After the construction of the panels they may be broken-out, buried, or incorporated in permanent works. Casting of panels and lifting at different stages allows the floor to be used several times. This is referred to as multi-stage casting. External crane positioning may release sufficient floor space for casting.
Several of the above options may be combined, but all must be considered carefully as they can affect speed, economics (especially crane time and capacity), and finish quality. When considering the radius of a crane, a plan of the crane on transparent film, with its outriggers and capacity at varying radii should be shown clearly on the drawings to determine the size and weight of the panels at different positions. The figure below shows a typical 50 ton crane and its radius of operation.
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Figure 2.1- Lifting Radius
Source: Tilt up Concrete Buildings: Design and construction Guide (2003) To ensure efficient operation and to minimise errors, drawings should clearly present all the necessary information in a form to suit site operations to ensure a successful job at the end of the day. A panel layout diagram must be shown illustrating the arrangement of the panels so that there would be room enough for the operation of the crane. The figure on the following page shows a typical arrangement of the panels. Note the walk out panel must be casted at the entrance so that it can be erected as the last panel externally. According to (Kevin McLouglin, 1996), a walk out panel is the last panel that is erected externally to enclose a building. Care therefore should be taken to ensure the crane is not restricted to come out.
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Figure 2.2 Panel arrangement on floor slab
Source: Tilt up Concrete Buildings: Design and construction Guide (2003)
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According to Dr. Jacqueline Glass (1998), all the shop drawings for the panels must be clearly indicated with each panel having its own drawing. To suit face-down construction these drawings must also show the view from the inside, with details of all openings, features, fittings and inserts to allow construction of the panel. Reinforcement may be shown on a separate sheet or view. Figure 2.3 - Inserts and fixing source
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Good dimensional control is best achieved using a setting-out drawing with both panel diagonals and running chainages, making minor variations self-compensating and providing checks for squareness (M.F Southcott and Alan Tovey, 1998). Figure 2.4 Typical panel setting out information
2.5.7 Cranage and crane movements Ideally, planning should involve the crane contractor and should mock-up all operations including bracing. A key objective is to optimise crane hook time and set-up time with lifting capacity. During planning it must be decided whether panels will be contiguous, share side forms, or be spaced apart. According to Kevin McLouglin (1996), having chosen an erection sequence and panel numbering to suit, panel casting positions will loosely reflect erection, with adjustment to suit corners and bracing. Provision must be made for crane access and exit. The 38
last panel is often set vertically in a temporary position next to the exit whilst the crane moves outside before completing the envelope. Where floor space dictates that stack-casting is necessary, the order and number of panels per stack should reflect the maximum that can be handled by the crane without relocating, and the constraints of placing and finishing the concrete to tolerance. 2.6 2.6.1 THE FLOOR SLAB AND CASTING SURFACE The Concrete Floor Slab Typically, the wall panels are cast directly on top of a tilt-up building's floor slab, so the floor slab must be constructed with great care. The floor slab should be level, and since the slab will become the form for the exterior face of the walls, any faults or imperfections will be identically reflected on the wall panels. The fabrication of a proper floor slab always begins with the subgrade. "The subgrade must provide non-sagging support for the concrete slab. Because the floor slab must bear the weight of the heavy panels and the mobile crane, it is important that it be well supported at all points by a thoroughly compacted subgrade". Typical tilt-up building concrete floor slabs range from five to six inches thick. In addition to strength considerations, the quality of the finished surface is very important. Proper vibration, screeding, finishing, and curing are essential to provide an adequate casting surface. 2.6.2 Cure Coats and Bond breakers "One of the least considered items...can also be one of the most important and is crucial to a successful tilt-up project. That is the type, use, and application of the curing compound and bond
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breaker" (Kevin McLouglin, 1996). Since concrete tilt-up panels will "mirror" the finish on the floor slab, a proper curing process for the floor slab is extremely important. Properly curing the floor slab will prevent cracks and other imperfections that may occur on the casting surface due to improper rates of hydration. Equally important as the use of a proper curing compound for the slab is the use of a bond breaker between the slab and the concrete tilt-up panels to allow the panels to break free of the slab without any adhesive forces being developed. A tilt-up panel poured directly on a concrete floor slab without a bond breaker would adhere to the slab and could not be lifted. The common practice for curing compounds and bond breakers is to use one compound that will perform both functions. The American Concrete Institute recommends using a combined curing agent and bondbreaker to insure "compatibility between these materials and [to] eliminate the possibility of the wrong product being used for either one of the functions". Under extreme conditions such as hot, windy conditions where the maximum curing efficiency would be required to limit hydration, separate chemicals may be required to obtain the required curing effect. Whenever a separate curing compound and bondbreaker are used, the manufacturer of the bondbreaker should be consulted to ensure the bondbreaker will still be effective when used in conjunction with the different curing compound. Curing compounds and bondbreakers are simple to apply. The curing compound should be applied to the floor slab as soon as the final finish work is completed. Since the final strength and surface quality of the floor slab is dependent on the maximum moisture retention, the curing compound should be applied thick enough to form an impenetrable water barrier to hold in moisture. Once the floor slab has cured and construction of the tilt-up panels has begun, the
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bondbreaker coat should be applied after the panel edge forms are set and before placing the panel's reinforcing steel and lifting inserts. Typical coverage for the bondbreaker ranges from 350 to 400 square feet per gallon. "Coverage may be tested by sprinkling water on the surface. Water should bead up. If it spreads and soaks in, an additional light application is indicated. Avoid over application. Do not spray the bondbreaker on inserts or reinforcing steel. The following are several factors that need to be considered when selecting a curing compound and bondbreaker: The bondbreaker should be placed on a clean and dry surface. Rain, excessive heat, and dirt may diminish the bondbreaker's effectiveness. Some manufacturers produce bondbreakers that are specifically designed for adverse conditions, and these special compounds should be used when necessary. According to Kevin McLouglin (1996), some bondbreakers oxidize quicker than others, and their effectiveness is diminished shortly after being exposed to the elements. If there will be long delays between the bondbreaker application and the pouring of panels, a bondbreaker resistant to the elements should be chosen. Will the panels be painted? Some bondbreakers leave a residue on the tilt-up panels, and this residue must be removed before paint can be applied. If the panels will be painted, it is important to use a bondbreaker that will not need any special preparation prior to painting. If the wall panels are going to be left exposed, a bondbreaker that will not leave stains on the concrete must be used. Some bondbreakers will leave stains on the panels.
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"If floor treatments will be applied to the floor slab after the panels are lifted, a curing compound and bondbreaker that will not leave any residue that will interfere with the bonding of the floor materials must be used. According to a publication by Tiltup Concrete Association (2011) any time there are
questions concerning the suitability of the casting surface, the curing compound, or the bondbreaker; the manufacturer of the product should be consulted. Once the concrete has been poured, it is too late to ask for assistance. 2.7 CASE STUDY GATEWAY SHOPPING CENTRE ( SOUTH AFRICA)
GATEWAY SHOPPING CENTRE - Mhlanga Rocks (1999) OWNER Old Mutual Properties MAIN CONTRACTOR Gateway Construction JV What is on offer at Gateway?

ARCHITECT Johnson Murray Architects
CONSULTING ENGINEER Tobbell Strech & Associates SPECIALIST TILT-UP CONTRACTOR Tilt Up Systems cc
Over 375 shops and restaurants, A skateboard park. Standing wave pools for surfing and body boarding including the worlds first double point break. 42
27-m high indoor climbing wall. (Highest in the world) 18 cinemas An IMAX theatre A childrens entertainment arcade
PROJECT INFORMATION: Total Size Gross Lettable area Parking Arcades/ Public areas / Malls Tallest panel Largest Panel Heaviest Panel Number of tilt-up elements Total gross area of elements WHY TILT-UP? A. QUALITY The power floated finish of the tilt-up panels was far superior in both quality and durability to the steel floated finish that would have been attainable with a brickwork and plaster alternative. Furthermore despite being used only as a cladding and not as a structural element tilt-up was cost competitive offering better value for money than any other alternative. 317 843 m2 126 487 m2 191 356 m2 19.7 m 19.7 m x 5.2 m 4T 357 Over 17 000 m2
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B. COST Tilt-up was able to achieve the aesthetic relief features required by the Architects simply and economically and with an accuracy and quality not possible with any other construction method. C. SPEED The speed of erection inherent in tilt-up construction enabled the contractor to weatherproof the building six months ahead of schedule thereby allowing more time for the complex internal finishes required to the internal mall areas The client requested that the contractor investigate alternative construction methods to the conventional brickwork and plaster solution to ensure a world class centre. As a result several options were investigated before finally selecting tilt-up as the best alternative. Meetings were held with the professional team to explain tilt-up construction and the benefits the system could bring to the development as well as to resolve how tilt-up could meet the specific requirements of the project. Site visits to completed projects were arranged so that the team could see examples of the quality of finish attainable. Before proceeding the client authorized that a full size mock-up of a corner of the building be built in order that various details could be tested to ensure that they worked practically. Four wall panels each about 13m x 5m, a corner element and two tilt-up columns were formed, cast and erected. A first floor slab was cast and roof steelwork erected.
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D. FLEXIBILITY The owners then raised concerns over flexibility and how tilt-up could accommodate changes due to tenant requirements. The perception was that tilt-up was an inflexible building method. A report was prepared that looked at every conceivable change that might be required, from cutting openings in a panel to removing the entire bottom half of a panel and even the removal of complete panels. Tilt-up was able to accommodate all eventualities and in most instances accommodated the changes better than either brickwork and plaster or conventional precast. As a demonstration a door opening was cut into one of the mock-up panels and a frame and door installed. Towards the end of the project tilt-up proved invaluable in accommodating openings that were required for air conditioning ducts, fire escapes and other services. Openings were cut in panels that had already received their final coat of paint and with minimal disruption, mess and touchup required, tilt-up met the demands of flexibility with flying colors. Plate 2.21 A complete tilt up building with curves
Source; Master Mason, (2011)
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CHAPTER 3
RESEARCH METHODOLOGY 3.1 Introduction This chapter describes the procedures that will be used to conduct the study. In an ever changing world that is ever creating new possibilities, a greater challenge is being exerted to the effectiveness of the existing theories and technologies. This has attracted a necessity to carry out a critical comparative analysis of the conventional methods of building in regard to new technologies such as tilt up construction. In order to draw a well guided conclusion on which building system is more suitable than the other, a research weighing these issues must be carried out using a relevant procedure. A relevant methodology involves a procedural plan that is adopted by the researcher to answer questions vividly, objectively, accurately and economically. 3.2 Research Design: The study utilizes a descriptive form of research that attempts to provide information on the efficiency of tilt-up construction as a method of delivery of low rise commercial buildings. This will be done through three case studies of firms that have attempted using concrete panels in their construction. Tiltup construction as earlier said is similar to precast panels with the difference coming up on the mode of construction, size of panel and design in that the tilt up panels act as load bearing panels.
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These firms are: Seyani Brothers Warehouse construction at Tononoka, Embakasi. H-young Construction Company. Economic Housing Group, Industrial Area, Nairobi.
The tools used to collect data are: questionnaires, interview schedules, photographs and field notes of observations. Both qualitative and quantitative methods will be used for data analysis. Advantages of using both qualitative and quantitative methods: Some of the objectives in this study are better assessed using qualitative methods while others are better assessed using quantitative methods. Qualitative methods provide in-depth explanations while quantitative methods provide the hard data needed to meet the required objectives hence both methods supplement each other. For example the subjectivity associated with qualitative research is minimized by the objectivity of quantitative research. The finding derived from the one approach of either validates the other. 3.3 Nature and sources of data: The study makes use of two types of data namely: Primary data. Secondary data.
Primary data offers firsthand information, opinion and views from companies practicing tilt-up construction. Secondary data becomes important in the manner that it provides both unpublished and published data to support and make comparison with the primary data that is gathered. 47
3.3.1 Primary data The information from primary data will be gathered through the use of self-administered questionnaires to be conducted with heads of the construction companies named earlier. Interviews are also to be conducted with developers that are practicing tilt up construction in Kenya. In each of these cases; the researcher will seek opinions and views with regard to the use of tilt up construction as a value-engineered process in regard to quality, cost and speed in delivering commercial building in Kenya. 3.3.2 Secondary data: The sources of secondary data will include use of publications recorded to support the argument in this research paper. Data will be obtained from previous research articles, scientific journals, books, internet based data, reports from seminars, associations and magazines. 3.4 Target population and sampling frame The targeted population of this research will be three contractors based in Nairobi who have the capacity to practice tiltup concrete technology. The results of the study are generalized on both private and public sectors of the building industry. 3.4.1 Sample size: Intelligent discrimination will be used to select three building contractor with the capacity to handle tilt up concrete technology.
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3.4.2 Sampling methods: This study uses both purposive and simple random sampling techniques. The three building firms; H-Young, Seyani Brothers and construction Company economic Housing Group will be selected purposefully.
3.5 Methods of data collection and instruments: The quality of a research study depends to a large extent on the accuracy of the collection procedures. Descriptive data is collected in this study through interviews, questionnaires and observations to address the objectives of the study. The instruments used are interview schedules, questionnaires and note book. 3.5.1 Interview schedules. It is used to standardize the interview situations so that interviewers are asked the same questions in the same manner where some structured questions are asked together with open-ended ones. One method of collecting recording data during the interview is through note taking.
3.5.2 Photographs. They are useful in illustrating the production systems and the physical elements of tilt up technology as a building method. 3.5.3 Questionnaires. This refers to list of questions that are to be administered to the sampled respondents. The question will however be structured so as to assist in obtaining the relevant information
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necessary for the research. This instrument was chosen because of its effectiveness to eliminate biasness and provide freedom to the respondents to answer as they see fit.
3.6 Methods of data analysis and presentation: After the data has been collected using the relevant tools using the relevant tools using the recommended procedure and techniques that enables it to be coded such that it is computed. This study yields qualitative and quantitative data and analysis seeks to draw a general conclusion on how categories of data are related. Data coding starts in the field and is done as the data is being collected and then it is organized into themes and concepts and from these, theories and generalizations are formulated. Data analysis and collection are done simultaneously. The data will be statistically analyzed using the method of descriptive statistics. Data analysed is presented in a report which is narrative, giving an analytical view citing the significance and implications of the findings. Statistical methods are used to analyze the quantitative data and this scientific tabulation is done by a series of methods such as: 3.6.1 Pie Charts: This form of presentation will be used to represent opinions gathered from various respondents regarding the use of tilt up construction. The data in this view will be computed as percentages. 3.6.2 Tables: They will be used to indicate statistical manipulation employed. This can be information processed from checklist.
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3.6.3 Bar graphs: They represent data that will have been formulated in table forms from the questionnaires. 3.7 Statistical analysis: The data collected by the above methods will be analyzed through the use of descriptive statistical measure of central tendency. This approach will be used as the main support to the problem area; it is applicable to results obtained from structured questionnaire and interviews. Basic documents such as graphs, tables, charts, distribution and measures of central tendency will be used to analyze data collected. The following shall be used to analyze data collected. 3.7.1 Mean: This is where the required responses are evaluated by calculating the averages of the responses are given. In this case mean, indicates general trend of all respondents.
3.7.2 Mode: This is where response options, which are given by the majority of the respondents is taken into considerations. 3.7.3 Range: This will be used to show the extremities in the research from the data collected within the respondents showing divergent views of each of them. 3.7.4 Standard deviation: This will be used in the analysis of the datas cohesiveness. Comparison of the relationship shall be used to evaluate the consistencies of the feedback given the respondents on the field questions in the questionnaires.
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3.7.5 Percentiles: This is where various responses in each choice, where a variety of options are given. 3.8 Comparative techniques: This approach will be used as the main support to the statistical analysis. It will be used on the subjective and qualitative evaluation of data gathered from questionnaires, interviews and literature review. 3.8.1 Reliability of data: The reliability of data collected is concerned with the consistency, that is, the probability of obtaining the same kind of data if the study were to be conducted again. The questionnaire contains attitudinal questions and no single questions. This enhances the reliability of the data if the study were to be conducted again. This also enhances the reliability of the results of subjective judgments. Reliability is enhanced by the use of interactional checks through direct observation. Use of various sampling techniques frees the result from random error. 3.8.2 Validity of data: The validity of data collected from the field is concerned with checking the respondents account with what really exists. To ensure validate in the survey, the study seeks only to measure what is necessary. Right application of tools of data collection reduces the interfering variables. The validity of the data is enhanced through: (a) Application of the appropriate data collection techniques, pre-coded observation checklists is systematically applied on the field study. (b) Application of well-selected sampling procedure on the field.
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(c) By using carefully and properly composed questions that cover all the proposed areas of study.
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CHAPTER 4 DATA PRESENTATION AND ANALYSIS 4.1 Introduction Out of the 30 questionnaires issued to gather the required data only 19 were received back. This reflects about 66%, which will offer the basis of analysis for this study. Below is the actual summary of the distribution of the respondents from each category. Table 4.1 - Distribution of the target samples. Participants Contractors Structural Engineers Target No. 25 5 Actual No. 16 3
Source: Author field work, July 2011 Contractors and Structural Engineers were the target population in this study. Planning for tiltup both for lifting and placing is the sole responsibility for both the Contractor and the structural Engineer. This was therefore the main reason for choosing them as participants of the construction industry. The design for lifting moments of this shear walls is critical for the success of a tilt up job to be successfully achieved. The type of crane used by the contractor will basically affect both the time and cost to successfully carry out the tilt up job. Main contractors based in Nairobi have also in a way attempted different construction method and therefore have the capability to offer a drawn conclusion on which method is more viable compared to the other emerging technologies.
54
4.2 Method of construction Contractors in the country have basically failed to adopt emerging technologies to change the face of the construction industry in Kenya. Despite the advents made in the introduction of ready mixed concrete and the introduction of mobile cranes in the last century; contractors in Kenya have clung to old conventional ways of building through the use of formwork and concrete in putting up the structures of commercial project. Out of the received results 75% of them put up there structures by insitu concrete; 12.5% have used factory precast components to put up structures and 12.5% have casted there panels on site and tilted them up to their final position. Graph 4.1 Methods of Construction
Method of construction used by contractors

Conventional Precast Tiltup walls
80% 70% 60% Percentage 50% 40% 30%
20%
10% 0%
Method of construction
Source: Author field work, July 2011 55
4.3
Cost overruns
Contractors who have been using conventional methods to put up commercial structures such as go down shared the fact that they experienced cost overruns in their projects. Most of the contractors admitted that they delayed the project handover by at least three months to five months of the anticipated handover time in the schedule of works. The contractors attributed the cost overruns of the project to various factors such as: i) Inflation of the cost of material. ii) Low labour productivity. iii) Poor material management on sites. iv) Poor quality control. The contractors doing precast admitted having substantial cost savings in their projects but admitted that precast has its challenges especially where there are design changes leading to rejection of transported panels. They attribute the substantial cost savings to the following points: i) Placing panels in place is faster than using conventional methods. ii) The labor required is practically smaller than the labor of insitu concrete. iii) The cost of building finishes such as plastering is minimized. The contractors doing tilt up jobs attribute their cost savings to the fact that: i) Quality can be controlled on site. ii) Transportation costs are eliminated dealing away with expensive bracings. iii) The size of the panels are far much larger than those of precast allowing for greater allowance of height required for go downs and other commercial buildings. 56
The summary below presents summary of how these three methods compare in cost overruns in their projects. Graph 4.2 Cost Overruns Percentages of cost overruns in a project 12.00% 10.00% 8.00% 6.00% 4.00% 2.00% Convectional Precast Tiltup walls
Percentages of cost overuns
0.00%
Method of construction
Source: Author field work, July 2011
4.4 Time overruns The contractors who use conventional methods share the views that there will always be time overruns in the projects and schedule of works is created to win tenders and meet the local regulations and not necessarily for planning purposes in the construction industry.
57
The contractors are all of the view that the process of putting structures in use is cumbersome and involves a lot of time to assemble formwork and put up structures to form buildings. The contractors admitted that they face time overruns ranging from 3 months to 9 months in their projects. Contractors doing precast all viewed that their method of putting up structures is time efficient and that they rarely face any time overruns if any. The tiltup jobs that have been done by contractors confessed that they in fact had achieved time savings by achieving cost savings in their projects. Graph 4.3 Time Overruns Average No. of months that projects experience time overruns
6 5
4
No of months 3 2 1 0 Method of construction
Conventional Precast Tilt up walls
-1
4.5 Tilt up construction and its construction: The method of casting tilt up walls on site has not been well utilized in Kenya. 30% of those interviewed said that they are aware of this mode of putting up structures but they said there was no code regulating its usage in the country. 50% of those who said they had used this method of construction; had used it in private development. They acknowledged that casting panels on site reduced the time it takes to construct a structure and that it required a relatively smaller crew than that of conventional building methods. The contractor however claimed that the process requires careful planning; restricted design changes and adequate materials such as bondbreakers to ensure a successful job. 12.5 % of those targeted claims that they have used tilt up on site because of the following reasons: i) Speed of construction. ii) Cost of savings. iii) Developers preference. iv) Quality of tilt up jobs. v) Easy of applicability of tilt up technology.
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Most contractors who have used this kind of technology in their work also combined some of the above factors as to why they opted for such jobs. These results can be summarized in the chart below. Chart 4.1 Option for tilt up construction
Option for tilt up construction

Speed Cost Quality Applicability Developer's preference
12% 33% 15%
18% 22%
Source: Author field work, July 2011 4.6 Comparison matrix between building methods The structural engineer who had experience tilt up job also answered that they had also done contracts that involved both convectional masonry work and also had experience with factory precast elements. The structural engineer gave out a comparison matrix between the three construction methods in his own opinion.
60
Table 4.2 - Performance Comparison Matrix Conventional Construction 1 1 1 2 1 1 2 1 10 Precast Construction 2 2 2 3 3 3 3 2 20 Tilt-up Construction 3 3 3 3 3 3 3 3 24
Criteria Constructability Weather Resistance and Durability Thermal resistance Fire resistance and safety Flexibility in applying finishes Maintenance Aesthetics Sustainability Total score
Source: Author field work, July 2011 The engineer was asked to give his personal opinion based on the above stated factors and rate the construction methods out of a possible score of 3 for each of the variables in the interview. The performance can be expressed in form of chart to illustrate the method that fairs well compared to the others. 61
Graph 4.4 - Performance Comparison matrixes Performance matrix

3.5
2.5
Performance Score
1.5
0.5
0 Constructability Durability
Conventional 1 1 1 2 1 1 2 1
Precast 2 2 2 3 3 3 3 2
Tilt-up Construction 3 3 3 3 3 3 3 3
Thermal resistance
Safety Finishes Maintenance Aesthetics Sustainability
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4.7 Tilt up construction in Kenya The respondents in the field study felt that there are challenges facing the use of tiltup in Kenya. One of the respondents answered that there was no competent company to provide both the bond breaker and the lifting inserts that can support that kind of a job in the country. However most of the respondents admitted that they are not conversant with that kind of method and that the equipments necessary to carry out tilt up may not be available in the country soon. The following chart shows a representation on why respondents thought that this method has not been adopted well in the country. Chart 4.2 Adoption of Tilt up in Kenya
Why not adopted in Kenya?

Lack of Knowledge Taste and preferences Cost effectiveness Lack of equipments Design restriction
28% 39%
5%
17%
11%
63
4.8 Future of Tilt up concrete in Kenya With adoption of value engineered approach in the construction industry in Kenya; around 40% of the respondents agree that it is time the country adopted emerging technologies in the industry. Below are the results in of a graph about how the contractors felt about the future of this method Graph 4.5 Future of Tilt Up Construction Future of tilt up construction
50.00%
45.00%
40.00%
35.00%
30.00%
Strongly Agree
25.00% Agree Disagree 20.00% Strongly Disagree Dont know 15.00%
10.00%
5.00%
0.00%
Attributes
4.9
Cost Analysis between Conventional, Precast and Tilt up construction
4.9.1 Conventional analysis In order to give a clear cost analysis between different construction methods; the researcher carried out an analysis of a low rise story building in order to give a solid ground of the argument that tilt up construction is an effective method of putting up low rise building structures. Plate 4.1 Two storey conventional masonry faade
Source: Author secondary data, July 2011
65
Table 4.3 - Surface area analysis of the faade (conventional method) Description Area (Sqm) Openings Concrete columns/lintels Concrete Parapet Masonry Blocks Faade area = 15.2 18.32 8 22.48 64 24% 29% 13% 35% 100% % of the total
Source: Author Secondary data, July 2011 Conventional method of building is the most common method used in putting up building structures for low rise buildings in the country. The researcher opted to use the cost per square meter to carry out the analysis for this study. The result for the analysis are presented in the summary below.
66
Table 4.4 Conventional cost analysis SN 1 2 3 4 5 6 7 8 9 10 11 Description Concrete columns Concrete Slab edge Window Lintel Door arched lintel RC Parapet 200mm thick block supply inclusive of wastage Fixing of block including mortar and accessories. External Rendering. Internal Plaster Opening surrounds plaster Decorative plaster Total Average cost per sq meter of Faade = Source: Author, Secondary data, July 2011 Unit CM CM CM CM CM SQM SQM SQM SQM M NO Quantity Unit cost (Ksh) 2.1 1.28 0.192 0.512 1.2 22.48 22.48 56.8 34.4 36.4 12 12000 7500 10000 15000 10000 1200 500 700 700 200 800 58600 Total (Ksh) 25200 9600 1920 7680 12000 26976 11240 39760 24080 7280 9600 175336 2740
The average cost for putting up and finishing the faade per square meter was found to be 2740 ksh according to the analysis done for the conventional mode of putting up a low rise structure.
67
4.9.2 Precast Analysis The researcher then carried out an analysis of a similar faced shown in the figure below but incorporating sandwich panels that offer the advantage of provision of thermal insulation for the entire structure. Plate 4.2 - Two storey precast faade
Source: Author Secondary data, July 2011
68
Table 4.5 Precast cost analysis SN 1 2 3 4 5 6 7 8 9 10 Description Concrete columns Concrete Slab edge Window Lintel Door arched lintel RC Parapet 150mm concrete Joining at the columns External Rendering. Internal painting Transport cost Total Average cost per sq meter of Faade = Unit CM CM CM CM CM CM Item SQM SQM No. Quantity Unit cost (Ksh) 2.1 1.28 0.192 0.512 1.2 3.372 56.8 34.4 4 12000 7500 10000 15000 10000 12000 400 400 500 67800 Total (Ksh) 25200 9600 1920 7680 12000 40464 8092 22720 13760 2000 143436 2241.19
Source: Author Secondary data, July 2011 The average cost for putting up and finishing the faade per square meter was found to be 2240 ksh according to the analysis done for the precast mode of putting up a low rise structure.
69
4.9.3 Tilt up construction cost analysis: The researcher then carried out an analysis of a similar faade shown in the figure below using the concept of tilt up developed in this studys literature review. The comparison was then done to know which method offers a more cost effective method of constructing low rise commercial buildings. Plate 4.3 Two storey tilt up construction faade
Source: Author Secondary data, July 2011 Tilt up construction adopts its own panels as load bearing walls and therefore eliminates the use of columns to offer load bearing piers to the structure.
70
Table 4.6 Tilt up Cost Analysis SN 1 2 3 4 5 6 7 8 9 10 11 Description Concrete wall 15 cm thick including reinforcement Concrete Slab edge Lifting inserts Crane hire Bracing hire 3no. Bracing inserts Bond Breaker Panel base grouting Surface preparation Opening surrounds plaster Furring Channels Total Average cost per sq meter of Faade = Unit CM CM No. hr week No. SQM M SQM M SQM Quantity Unit cost (Ksh) 5.372 0.64 8 1 6 8 61.296 8 56.8 36.4 34.4 12000 7500 500 4000 1000 500 50 200 150 150 500 26550 Total (Ksh) 64464 4800 4000 4000 6000 4000 3065 1600 8520 5460 17200 123109 1925
Source: Author, Secondary data, July 201 The average cost for putting up and finishing the faade per square meter was found to be 1925 ksh according to the analysis done for the tilt up construction mode of putting up a low rise structure. From the above three analysis it can be shown that tilt up offers a significant cost
71
savings that can be attributed to both time taken, reduced labour and simple finishes such as skim coating that gives tilt up the versatility and aesthetics value desired in commercial buildings. 4.10 Comparative study between different building methods in Kenya a) Tilt up construction and Precast constructions
The main advantage of tilt up construction over precast is that tilt up is carried out on site and tilted to its final position through the use of powerful outrigger cranes due to the enormous sizes of the panels. Apart from that, the transportation cost for precast concrete is eliminated together with the additional supports for the precast concrete. The table below shows the advantages that tilt up offers over precast concrete. Table 4.7 Tilt up verses Precast comparative study Tilt up Concrete and Reinforcing steel Load bearing Panels Height up to 27 metres Width up to 15 metres Fewer panel joints Casting area = building slab Erect in 8 to 12 weeks Quality Control on site Precast Concrete and reinforcing steel Non load bearing panels Height up to 12 metres Panel width up to 3.5 metres More panel Joints Casting area = bed in a plant Erect in 12 to 16 weeks Quality control at plant Advantages Equal Tilt up Tilt up Tilt up Tilt up Tilt up Tilt up Tilt up
Source: Author, Secondary data, July 2011
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b)
Tilt up and Conventional Masonry
Tilt up offers major benefits both during construction and after construction. The labor time taken complete a masonry building is escalating and the cost spent on building finishes are also not developer friendly. Furthermore, the cost of maintaining a masonry building is great. The table below illustrates the advantages that tilt up offers over conventional masonry. Table 4.8 Tilt up verses Conventional Masonry Tilt-up Dense concrete matrix Joints between panels only Conventional Masonry Less dense concrete matrix Horizontal and vertical joints at every units Integral reinforced concrete beams above openings. Constructed on the ground Easy to form arches Steel lintels and continuous concrete beams above openings Built from scaffolding Arches require temporary forming Tilt up Tilt up Tilt up Tilt up Advantage Tilt up Tilt up
Less labor, shorter schedules More labor, longer schedules
Source: Author, Secondary data, July 2011 4.11 Machinery According to the respondents with a positive view believe that to carry out a tilt up construction requires a high initial investment for an outrigger crane that can be used to lift heavy panels that can climb up to 6 stories in height. 73
The respondents admitted that the cranes currently available in the country have a capacity of around 50 tons and are only suitable for tilt up jobs that are of two to three storey in height. 4.12 Conclusion Following the trends shown in the data analysis through the primary and secondary data, tilt up construction has shown to be a smarter way of building the day. This method that offers speed, economy, architectural versatility and durability. A successful tilt up project begins long before the first panel is cast. Panel layout, staging and movement of materials and the erection sequence are just a few of the many tasks that must be decided before construction begins. Tilt up calls for good management techniques, planning and execution of the work in order to reap the best out of it. However it must be noted that due to the initial cost of investment; tilt up should be restricted to large commercial projects. Lack of knowledge and fear has been credited in this research as the major impediments to adoption of value engineered processes such as tiltup construction.
74
CHAPTER FIVE SUMMARY, CONCLUSION AND RECOMMENDATION 5.1 Introduction The aim of the study was to explore on the adoption of tilt up construction as an effective method of delivering low rise commercial buildings as way to reduce time and cost overruns. Therefore this sections seeks to highlight the strong linkage between the research objectives and the research findings, and make suitable recommendations. Objectives were set at the onset along which the research was to be carried out. The literature having been reviewed and data collected from the field analyzed, it is logical to compare the findings against the set objectives and make clear cut conclusion. However there were limitations during collection of data. 5.2 Findings To achieve the purpose of the study the following objectives were set at the onset of the study: i) To find out different methods of construction used in Kenyas construction industry. ii) Establish the awareness of tiltup construction in the industry. iii) To find out the benefits of tilt up construction over other building methods. iv) To study the construction design and process of a tiltup wall building. v) To recommend the suitability of using tilt up construction in Kenyas construction industry.
75
5.2.1 Methods of construction used in Kenyas construction industry Currently, the country uses conventional methods of building through the use of insitu concrete, traditional precast and at rare circumstances uses tilt up concrete construction. Conventional method was the most widely used method of construction. The contractors interviewed felt that they did not have the capacity and technology to get them past in situ concrete. Those contractors using precast only depend on one manufacturing plant owned by one of the leading cement manufacturing plant in the country. They have opted for this form of construction because feasibility studies have shown acceptance of the precast technology by the end user of the product. Tilt up technology is rare in the country; with the proponents of the technology arguing that there are no materials and advanced equipment to carry out a major tilt up job. However through the cost analysis done; tilt up construction shows that it is competitive in terms of cost, economy, durability and speed. These indicators are also backed by strong support from countries that have adopted this form of technology. 5.2.2 Establish the awareness of tilt up concrete technology in Kenya This objective addressed in the field study. It was established that there is lack of awareness of this mode of construction. Those who are aware of the technology and used it agreed that it offered an excellent form of putting up commercial buildings especially large go downs and warehouses where security comes in handy.
76
5.2.3 Benefits of tilt up construction over other construction methods Tilts up panels have proven to be panels to beat. There benefits have been shown from the results of the secondary data; case study and the literature review. Tilt up does not just offer benefits during construction only but also during the usage of the building. A building done with tilt up often attract lower insurance premium, low maintenance cost, high thermal insulation capacity amongst others. During construction tilt up has shown benefits in form of reduced labor, accelerated schedules and economy in form of construction. However this method of construction also has its own shortfalls that include: Tilt up requires cranes of large capacity that may not be available in the country. Tilt up is not suitable for confined sites. Tilt up is not suitable for high rise buildings and residential housings.
5.2.4 Construction design and process of building a tilt up building: The process of building a tilt up building has been tackled at great depth in the literature review of this document and through a case study. Tilt up building utilizes load bearing panels as wall panels. The approach to design of tilt up panels is done in a similar manner to those of shear forces taking into account lifting moments. BS 8110 gives the design consideration and loading factors that should be considered in procedure for shear wall design.
77
5.2.5 Recommend the suitability of using tilt up construction in the industry Tilt up construction is a method that can be used for construction of large low rise commercial buildings such as go downs, ware houses and office blocks. Projects that present tight schedules and shortage of labor should consider adopting tilt up construction for the projects. 5.3 Summary This research sought to identify different methods of construction used in the country, indentify their advantages and disadvantages. This established the need to look for alternative construction method that can deliver an environmentally friendly building system that offers compressed schedules together with cost savings. This led to the identification of tilt up construction that enabled analysis of the process and its cost implication in comparison with other building systems in the country. 5.4 Recommendations The researcher recommends that structural engineers in the country should develop a tilt up code to govern the construction of tilt up buildings. The government should also organize seminars to make the parties in the construction industry aware of the alternative technologies that will make the country sustainable. 5.5 Further areas of research a) Alternative materials for use in tilt up concrete b) Comparison of steelcrete structures verses tilt up concrete construction in tilt up concept.
78
Bibliography Glass, J. (1998). Evaluation of tilt-up construction in relation to selected UK building types. Post Graduate Research School, School of Architecture, Oxford Brookes University, UK. (PhD thesis). Standards Australia. (1990 ). Tilt-up concrete and precast concrete elements for use in buildings. Part 1: Safety requirements. Part 2: Guide to design, casting and erection of tilt-up panels. Standards Australia, North Sydney, NSW, AS 3850. 16 pp, 24 pp. Cement and Concrete Association of New Zealand. (1991). Tilt-up technical manual. C&CA, Porirua, New Zealand. Brookes, H. (1997). The tilt-up design and construction manual. HBA Publications, Newport Beach, Dayton, Ohio, USA. Spears, R, E (1999). Tilt-up construction and design considerations. Concrete International. OHagan, R.(1989). The incredible rise of tilt-up construction. Australian Concrete Construction. Vol. 1, No. 1. Tilt-up Concrete Association.(1996). Video: Tilt-up concrete construction. Published in the UK by the Reinforced Concrete Council, Crowthorne. Azizinamini, A, Glikin, J. D, Oesterle, R. G.(1994). Tilt-up wall test results. PCA, Skokie, USA. Tilt-up Concrete Association.(1996). Safety checklist for tilt-up concrete construction. TCA, Mount Vernon, USA, 1996.
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Construction Industry Board. (1996). Towards a 30% Productivity Improvement in Construction, London, Thomas Telford. Dey, I. (1993). Qualitative Data Analysis; a User Friendly Guide for Social Scientists, London, Routledge. Glass, J. (1997). Tilt-up Prove the Panels to Beat, Concrete Quarterly, Spring Gray, C. (1997). Can Construction Management Deliver Value? Institute of Civil Engineers, Better Value Building: Structuring the Building Industry to Deliver Value, London. Institute of Civil Engineers (1996). Creating Value in Engineering; ICE Design and Practice Guide, London, Thomas Telford. Martin Southcott, & Alan Tovey. (1998). Tilt-up concrete building: Design and Construction guide.
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APPENDIX A: A1: SAMPLE QUESTIONNAIRE Iam a 5th year studentundertaking an undergraduate course in construction Management at Jomo Kenyatta University of Agriculture and Technology (JKUAT). I am currently doing a research project on Adoption of Tiltup Technology for low rise commercial buildings in Kenya. Herein is a questionnaire that will help me in gathering the required information to finalize the research. Your assistance by answering the question will be highly appreciated. Confidentiality is assured on all sources of information given. Guidelines 1) Select an option of your choice through use of a tick [] or a cross []. 2) Kindly complete the questionnaire honestly and to the best of your knowledge. 3) Where the question does not apply to you, indicate by writing N/A. Contacts Maingi Kiriinya Kevin +254 723 042 190 kevinkiriinya@gmail.com C/O Department of Construction Management, JKUAT P.O BOX 62000-00200, Nairobi.
QUESTIONNAIRE TO BE ADMINISTERED TO CONTRACTORS: 1) Have you ever been involved in a construction of a commercial projecte.g. go down or warehouse inNairobi? a) Yes a) Conventional b) Precast b) No c) Tilt up panels d) others . 2) Which construction method do you use often in putting up such structures?
3) If conventional in (2) above,did you experience cost overruns in the projects? a) Yes 4) If yes in (3) above, by what percentage? a) 0-10% d) 30-40% a) Yes 6) If yes in (5) above, by how long? a) 0-4months c) 9-12 months b) 5-9 months d) above 1 year b) 10-20% f) 40-50% b) No c) 20-30% g) Over 50% b) No
5) Did you have time over-runs in your project?
7) Have you used precast panels in a commercial building? a) Yes a) By trucks b) Manual a) Yes Comment .... b) No b) By train d) Other specify b) No ..... 8) What was the mode of transporting precast panels on site?
9) Did you face challenges in transportation of panels?
10) Doyou have time overruns in the projects? a) Yes 11) If yes in (10) above by how long? a) 0-4 months c) 9-12 months b) 5-9 months d) above 1 year b) No
12) Are you aware of tiltup technology as a construction method? a) Yes b) No
13) If yes in (12) above have you ever been involved in the use of tiltup technology as a construction method? a) Yes a) Economy d) Design 15) Did you have cost overruns in the project? a) Yes 16) If yes in (15) above, by what percentage? b) 0-10% e) 30-40% a) Yes a) 0-4 months c) 9-12 months b) 5-9 months d) above 1 year b) 10-20% f) 40-50% b) No c) 20-30% g) Over 50% b) No b) No b) Speed e) Quality c) Applicability 14) If yes in (13) above, why did you choose tiltup technology as a method of construction?
g) Others (specify)
17) Did you have time overruns in the project? 18) If yes in (17) above by how long?If yes in (10) above by how long?
19) In your opinion, why do you think the use of tiltup technology as a construction method has not been adopted in a higher scale in Kenyas construction industry? a) Lack of knowledge
b) Cost effectiveness c) Design restrictions d) Tastes and preferences e) Others (specify) ............
20) In your opinion is tiltup constructionmore viable than other conventional methods of construction? a) Yes b) No If yes why 21) The construction industry in Kenya is ready for Tiltup technology? a) I strongly agree d) I strongly disagree a) Precast b) I agree e) I dont know b) Conventional c) Tiltup walls c) I disagree
22) In your opinion which construction method is cheapest? d) Other (specify).
APPENDIX A: A2: SAMPLE INTERVIEW QUESTIONS 1) How would you rate the construction methods in Kenya and Tilt up construction? 2) In your opinion is tilt up construction cheaper than conventional methods of construction? 3) What challenges are associated with tilt up construction as a method of construction? 4) How flexible is insitu concrete flexible in comparison to factory precast components? 5) In your opinion how do tilt up, precast and conventional masonry compare in form of speed and cost of construction? 6) In case of discrepancies in design and the constructed panels, how do you manage this errors? 7) Is tilt up construction suitable for constrained sites? 8) Do you think that contractors in Kenya have the capacity to handle tilt up construction in form of skill and equipments?

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ADOPTION OF TILT UP TECHNOLOGY FOR LOW RISE COMMERCIAL BUILDINGS IN KENYA

BY MAINGI KIRIINYA KEVIN AB243-0192/06

Signed (Researcher); Date Maingi Kiriinya Kevin

Signed (C.O.D); Date Mr. Daniel Saiva

2.5.3 2.5.4 2.5.5 2.5.6 2.5.7 2.6

2.6.1 2.6.2 2.7

CASE STUDY GATEWAY SHOPPING CENTRE ( SOUTH AFRICA) ............................ 42

4.9.1 4.9.3 4.10 4.11

5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 5.4 5.5

CHAPTER 1 1.1 Introduction:

Significance of the study:

CHAPTER TWO LITERATURE REVIEW 2.1 INTRODUCTION:

THE CONCEPT OF TILTUP CONSTRUCTION METHOD

Plate 2.1 Casting slab

Source; Tiltup Concrete Association, (2011)

Source; Tiltup Concrete Association, (2011)

3) Plate 2.3 Placing brackets

4) Plate 2.4 - Dimensioning

5) Plate 2.5 Edge formwork

6) Plate 2.6 Complete surface

Source; Tiltup Concrete Association, (2011)

Source; Tiltup Concrete Association, (2011)

9) Plate 2.9 Embeds and inserts

10) Plate 2.10 Ready for Casting

1) Plate 2.11 - Concreting

2) Plate 2.12 Troweling

3) Plate 2.13 - Power floating

4) Plate 2.14 - Completion

5) Plate 2.15 Cured panels

6) Plate 2.16 Drilling for brackets

1) Plate 2.17 Bracings and Props

2) Plate 2.18 - Lifting

3) Plate 2.19 Guiding the panel

4) Plate 2.20 Bracing of props

Source; Tiltup Concrete Association, (2011)

Source; Tiltup Concrete Association, (2011)

Advantages of tilt up an alternative building method

PLANNING FOR TILTUP CONSTRUCTION:

Figure 2.1- Lifting Radius

Figure 2.2 Panel arrangement on floor slab

Source: Tilt up Concrete Buildings: Design and construction Guide (2003)

Source: Tilt up Concrete Buildings: Design and construction Guide (2003)

Source: Tilt up Concrete Buildings: Design and construction Guide (2003)

ARCHITECT Johnson Murray Architects

Source; Master Mason, (2011)

Method of construction used by contractors

80% 70% 60% Percentage 50% 40% 30%

Source: Author field work, July 2011 55

Percentages of cost overuns

Source: Author field work, July 2011

Conventional Precast Tilt up walls

Source: Author field work, July 2011 58

Option for tilt up construction

12% 33% 15%

Graph 4.4 - Performance Comparison matrixes Performance matrix

Source: Author field work, July 2011

Why not adopted in Kenya?

Source: Author field work, July 2011

Source: Author field work, July 2011 64

Cost Analysis between Conventional, Precast and Tilt up construction

Source: Author secondary data, July 2011

Source: Author Secondary data, July 2011

Source: Author, Secondary data, July 2011