A COMPARATIVE STUDY OF CONSTRUCTION USING · PDF fileInternational Journal of Civil Engineering and Technology (IJCIET ... A COMPARATIVE STUDY OF CONSTRUCTION USING ... reinforced

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International Journal of Civil Engineering and Technology (IJCIET) Volume 7, Issue 4, July-August 2016, pp. 100–110, Article ID: IJCIET_07_04_008

Available online at

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ISSN Print: 0976-6308 and ISSN Online: 0976-6316

© IAEME Publication

A COMPARATIVE STUDY OF

CONSTRUCTION USING SCHNELL

CONCREWALL® PRE-CAST SANDWICH

COMPOSITE PANEL AND RC MOMENT

FRAME WITH BRICK INFILL

Kaira Sneha

M. Tech, National Institute of Technology

Warangal, India

T.P.Tezeswi, Ph.D(UM), Postdoc (UCSD/UM),EIT

Assistant Professor, Structural Division, Department of Civil Engineering,

National Institute of Technology

Warangal, India

ABSTRACT

Developing countries especially those in Asia (India), are facing the

challenge of a growing middle class with greater demand for housing

facilities. Faster and more affordable methods of construction are being

sought after it, more than ever before as the action of emergency response.

Increased innovation aimed at reducing the cost of construction, and creating

affordable housing, is being integrated into methods of building and

construction. This has led to introduction of components pre-fabricated using

assembly line methods, in the construction process, which reduces the

negative aspects of in-situ construction such as theft, unreliable supply of

labor, unpredictable weather conditions, unprecedented fluctuations in prices

of materials and plenty of energy consumption.

A comparative analysis is conducted based on Discrete event Simulation

and Scheduling integration methodology in order to calculate duration of each

activity of construction process by EZStrobe and determine the resource

utility, productivity of resources for Schnell Concrewall and RC moment

frame with brick infill construction technologies. This research paper will

utilize time study method to determine the time taken by manpower and

equipment to perform each task and show advances in technology that are

making management of productivity, resource utility, cost, time which are

more predictable.. Two case studies were taken in order to have a

comparative analysis.

A Comparative Study of Construction Using Schnell Concrewall® Pre-Cast Sandwich

Composite Panel and RC Moment Frame with Brick Infill


Key words: Schnell Concrewall Panels, Discrete Event Simulation, Time

study, Productivity.

Cite this Article: T.P.Tezeswi and Kaira Sneha, A Comparative Study of

Construction Using Schnell Concrewall® Pre-Cast Sandwich Composite Panel

and RC Moment Frame with Brick Infill. International Journal of Civil

Engineering and Technology, 7(4), 2016, pp.100–110.

http://www.iaeme.com/IJCIET/issues.asp?JType=IJCIET&VType=7&IType=4

1. INTRODUCTION

Use of Expanded Polystyrene Panels (EPS) introduces a pre-manufactured technology

in the construction of reinforced concrete buildings. This industrial system entails

production of a panel of wavy/undulated shape of polystyrene which is covered on

either side with electro welded zinc coated square mesh. There are 33 connectors of

the square mesh per m2 to form a three dimensional reinforcement steel. There are

two kinds of polystyrene panels, single and double. A single panel has a polystyrene

sheet sandwiched between welded wire mesh on either side while a double panel is

made of two single panels which are joined with an intermediate cavity.

Building Materials and Technology Promotion Council, New Delhi described

Concrewall® construction system as a factory made system based on expanded

polystyrene panels (corrugated) reinforced with double mesh of galvanized cold steel

wires, interconnected to each other. To form the walls, the mesh is covered with a

coat of shotcrete applied under pressure using a pneumatic system [1]. A building can

go up to four floors with a single panel and fifteen floors in double panel. Assembly

of the finished panels is done on site. A single operator can lift and place the panels at

their respective design positions creating labor savings compared to traditional

construction techniques which requires several workers to put up a wall using

masonry stone and plaster [2].

1.1. Time study analysis

Time study is a work measurement technique for recording the times and rates of

working for the elements of a specified job carried out under specified conditions and

for analyzing data so as to determine the time necessary for carrying out the job at a

defined level of performance [3].

2. AIM

• To differentiate construction sequence or methodology of Concrewall building

systems and RCC structures.

• To compare the time and cost incurred when constructing a Residential building

using expanded polystyrene panels and conventional (traditional) method using RC

moment frame with brick infill.

• To develop an approach that enables use of discrete event simulation in scheduling of

construction operations i.e. simulation based scheduling.

3. SCOPE

The study is focused on a single story residential structure. The construction of an RC

& Schnell Concrewall® structure with identical floor plan and dimensions is studied

and compared to determine process of construction, resources required, constraints as

well total cost of construction. Major task of the project is to effectively utilize time

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study as well as discrete event simulation technique for determination of duration of

task, unit productivity and through detailed estimation of quantities cost analysis is

done for both systems.

4. METHODOLOGY

A. A brief introduction to Schnell houses in Jindal Steel power plant

Jindal Steel and Power Limited (JSPL) is one of India’s primary & integrated steel

producers with a significant presence in sector like Mining, Power Generat

Infrastructure. National wide it had two branches in Odisha and Chhattisgarh. During

the site visit to Angul, Odisha the following information is collected

• Schnell is a manufacturer of machinery for the production of innovative building

elements

• Schnell machinery for manufacturing EPS panels

Company, Angul. Polystyrene balls get imported from New Delhi for making EPS

sheets.

• JSPL Township consists of G+3 storey residential houses with Single panel structures

constructed for employees working with in industry shown in figure.

• There are other structures made of Schnell EPS panels integrated other building

systems :

• RCC + EPS Partition Wall Buildings

• EPS Wall Panel Buildings

• Combination of Hot Rolled Sections, Speed floor,

a)Completed G+3 Storey

c) RCC Moment frame wall panel building

Figure 1 Schnell EPS panel buildings integrated with other

T.P.Tezeswi and Kaira Sneha




4. METHODOLOGY



producers with a significant presence in sector like Mining, Power Generat


the site visit to Angul, Odisha the following information is collected:

Schnell is a manufacturer of machinery for the production of innovative building

chnell machinery for manufacturing EPS panels was installed within JSPL


JSPL Township consists of G+3 storey residential houses with Single panel structures

for employees working with in industry shown in figure.

There are other structures made of Schnell EPS panels integrated other building

RCC + EPS Partition Wall Buildings

EPS Wall Panel Buildings

Combination of Hot Rolled Sections, Speed floor, EPS wall panel buildings

a)Completed G+3 Storey EPS structure b) Panels being shotcreted

wall panel building d) Hot rolled steel and with panel erection

Schnell EPS panel buildings integrated with other construction sytems, JSPL, Angul

[email protected]





producers with a significant presence in sector like Mining, Power Generation and


Schnell is a manufacturer of machinery for the production of innovative building

installed within JSPL


JSPL Township consists of G+3 storey residential houses with Single panel structures

There are other structures made of Schnell EPS panels integrated other building

EPS wall panel buildings

Panels being shotcreted

panel erection

construction sytems, JSPL, Angul

A Comparative Study of Construction Using Schnell Concrewall® Pre

Composite Panel


B. Data collection and analysis

A. Single panels

a)Wavy undulated cross section

Figure

B. Shotcrete

• Cement, quarry chippings (dust) and sand are mixed in the ratio of 1:1:1 respectively.

A water cement ratio of 0.55 is used to realize a workable mix.

• Quarry chippings of 6mm size are used allowing the use of a turbo pump to spray the

shotcrete on the wall panels. Shotcrete is applied to a thickness of 17

C. Concrete

The ratio of concrete mix used as the cover for the floor slab is 1:1.5:3, being the ratio

of cement to sand to ballast (20mm). The concrete is corrugated to make a cover of

40mm for the slab

D. Wire mesh reinforcement

14 gauge galvanized steel wire mesh is used as reinforcement for the prefabricated

panel elements. Cold drawn and galvanized metallic wire with low carbon content,

stress tension up to 700 N/mm² and a constant diameter of 30 mm i

• Angular meshes

• Flat Meshes

• U Meshes

C. Building Procedure

1) Foundation

Foundations for the Concrewall

this research slab foundation is considered.

2) Wall panel erection

Anchoring rebar’s to foundation

Mark out and profile line wall positions

Starter bars should be either

the foundations and 400mm above

a) Electrical drilling machine

Figure 3

f Construction Using Schnell Concrewall® Pre-Cast Sandwich



Data collection and analysis

a)Wavy undulated cross section b) Thickness of expanded polystyrene foam

Figure 2 Polystyrene panel cross section

Cement, quarry chippings (dust) and sand are mixed in the ratio of 1:1:1 respectively.

A water cement ratio of 0.55 is used to realize a workable mix.

Quarry chippings of 6mm size are used allowing the use of a turbo pump to spray the

l panels. Shotcrete is applied to a thickness of 17-



Wire mesh reinforcement



stress tension up to 700 N/mm² and a constant diameter of 30 mm is used.

Concrewall system whether strip or slab are conventional. In

this research slab foundation is considered.

to foundation

Mark out and profile line wall positions

Starter bars should be either φ6mm or φ8mm, 500mm long with 100mm drilled into

the foundations and 400mm above.

drilling machine b) Drilled holes in the foundation

Figure 3 Installing anchor bars into foundation

Cast Sandwich

[email protected]

b) Thickness of expanded polystyrene foam

Cement, quarry chippings (dust) and sand are mixed in the ratio of 1:1:1 respectively.

Quarry chippings of 6mm size are used allowing the use of a turbo pump to spray the

-20mm.





s used.

system whether strip or slab are conventional. In

8mm, 500mm long with 100mm drilled into

Drilled holes in the foundation


All corners and wall joins must be reinforced

full height of the walls

3) Single panel roof installation

When the vertical panels are assembled on site, the verticality of the walls checked

and the bending meshes positioned on all the corners, it’s time to put the

bending meshes to connect the floor/roof to the vertical panels.

must be fixed in whole the perimeter of the floor /roof, at level of the

a) L mesh to join wall a

Figure 5

4) Window and door fitting

• To cut panels to fit and for door and window openings the wire must first be cut with

a wire cutter or angle grinder.

• Reinforcement around wall openings. Added steel mesh reinforcement is needed

around window and door openings to ensure no plaster cra

Mesh reinforcement strips of must be wire tied diagonally (45°) aro

before plastering.

• Fix a metal angle iron or hollow tube sub frame into the openings before plastering.

Fix and plaster these in place and then sec

a) Cutting the wire mesh b) Cutting of EPS Panel



Figure 4 Alignment of panels

All corners and wall joins must be reinforced with right angled wire mesh to the

Single panel roof installation


the bending meshes positioned on all the corners, it’s time to put the

meshes to connect the floor/roof to the vertical panels. The bending meshes

must be fixed in whole the perimeter of the floor /roof, at level of the intrados

join wall and roof panel b) Spacing of props specifications

Figure 5 Roof panel installation rules

Window and door fitting

To cut panels to fit and for door and window openings the wire must first be cut with

a wire cutter or angle grinder.

Reinforcement around wall openings. Added steel mesh reinforcement is needed

around window and door openings to ensure no plaster cracks form in these areas.

Mesh reinforcement strips of must be wire tied diagonally (45°) aro

Fix a metal angle iron or hollow tube sub frame into the openings before plastering.

Fix and plaster these in place and then secure the frames to the sub frame

b) Cutting of EPS Panel c) Mesh reinforcement strips

frame

Figure 6 Opening of wall panel

[email protected]

with right angled wire mesh to the


the bending meshes positioned on all the corners, it’s time to put the horizontal

The bending meshes

intrados.

b) Spacing of props specifications

To cut panels to fit and for door and window openings the wire must first be cut with

Reinforcement around wall openings. Added steel mesh reinforcement is needed

cks form in these areas.

Mesh reinforcement strips of must be wire tied diagonally (45°) around openings

Fix a metal angle iron or hollow tube sub frame into the openings before plastering.

e the frames to the sub frame

c) Mesh reinforcement strips d) Window

A Comparative Study of Construction Using Schnell Concrewall® Pre

Composite Panel


5) Electrical and plumbing installations

A hot air gun or torch is used to create channels in the polystyrene for the placement

of switch boxes, electrical conduits, cables or pipes.

6) Application of shotcrete

Application of shotcrete is done on both sides of the

thickness of 17-20mm is achieved. After about 30 minutes, mortar of 15mm thickness

is applied.

4.1. Comparative Study

4.1.1. Plan

In order to have a comparison between the RCC and Schnell Concrewall panel

buildings in terms of cost and time, a residential 2BHK building plan satisfying all the

vasthu norms is drawn in Auto cad and analyzed in terms of cost and time incurred

during construction.

Plan shown below consists of

1. Hall 2. Master bedroom 3

Figure 7

a) Wall panels alignment

Figure 8

4.1.2. Cost analysis of buildings

The main savings in cost when building using the expanded polystyrene are achieved

through reduced transport, labor and running and maintenance costs. The costs

f Construction Using Schnell Concrewall® Pre-Cast Sandwich



and plumbing installations


of switch boxes, electrical conduits, cables or pipes.

Application of shotcrete

Application of shotcrete is done on both sides of the single or double panel till a

20mm is achieved. After about 30 minutes, mortar of 15mm thickness

Comparative Study


s of cost and time, a residential 2BHK building plan satisfying all the


Plan shown below consists of

bedroom 3. Children bed room 4. Kitchen 5. Balcony

Figure 7 Single storey Residential house plan

Wall panels alignment b) Roof panels alignment

Figure 8 Wall and roof panel alignment

Cost analysis of buildings

cost when building using the expanded polystyrene are achieved


Cast Sandwich

[email protected]


single or double panel till a

20mm is achieved. After about 30 minutes, mortar of 15mm thickness


s of cost and time, a residential 2BHK building plan satisfying all the


Kitchen 5. Balcony

Roof panels alignment

cost when building using the expanded polystyrene are achieved




involved in construction were analyzed by detailed estimation of material quantities

and labor charges involved in construction of both buildings.

The following notes below were used to compute the material costs of the

building

RCC Brick infill structure:

• Perimeter of house 1015sft (35’x29’2”)

• Height of the storey is 10’6”

• Density of cement 1440 kg/m3

• Quantity of cement used for 1m3 of concrete (1:1.5:3), generally it is assumed that

percentage of voids occupied for a given quantity of concrete is 57 percent.

• Cement: 1/5.5x 1.57x1440=8bags

• Steel: Conversion factor for 1meter length of Fe415 steel in terms of

kilograms if d2/162.2, where‘d’ is the diameter of steel rod.

• Brick: Common burnt non modular clay bricks of size 23x13x10 cm size are

used whose dimensions with cement mortar are 24x14x11cm

• Depth of reinforced slab of 6”

Schnell EPS building:

• Panel area (1.2m by 3m) = 3.6 m2

• Cost of a wall panel including transportation cost per m2 = 110 rupees

• Cost of a wall panel including transportation cost per m2 = 160 rupees

• Number of labors in a team = 7members

Table 1 Material Cost estimation for RCC Moment frame with brick infill structure [4]

Material Quantity Unit Price per

unit

Net

amount in

rupees

Bricks non modular 8880 No’s 5.50 48840

43 grade Cement required for sub

structure and super structure including

brick work mortar

620

Bags

330

204600

Reinforcement bars of various diameter

i.8mm diameter bars 2669 kgs 46 122774

ii. 12mm diameter bars 1725 kgs 44 75900

iii.16mm diameter bars 400 kgs 44 17600

40mm aggregate/stone ballast for PCC 160 cft 23 3680

20mm stone ballast for columns, slab,

stairs 2192 cft 25 54800

Coarse sand for sub and super structure 1237 cft 45 55665




Table 2 Material Cost estimation for Schnell EPS Panel structure

Material Quantity Unit Price per unit Net amount in

rupees

Steel reinforcement cost

i. 8mm diameter bars 828 kgs 46 38088

ii.10mm diameter bars 240 kgs 45 10800

iii.12mm diameter bars 250 kgs 44 11000

Schnell Wall Panel of

100mm thickness 1400 Sq. ft 100 140000

Schnell Roof Panel of

thickness 160mm 1000 Sq. ft. 160 160000

Cement for M20 grade

concrete 500 bags 330 16500

Coarse Sand for M20

grade concrete 560 cft 45 25200

Coarse aggregate for

M20 grade concrete 1220 cft 25 30500

4.1.3. Duration analysis by Simulation

Time study analysis is conducted in order to obtain durations taken by each task in the

activity. The activities are captured in the video so that series of durations can be

noted for each task at different locations on construction site .Then distribution fitting

using Easy Fit software is used to obtain the best fitting curve for the continuous

duration points of tasks noted from video.

• Schnell EPS panel Building

Activity 1: Earthwork Excavation

Soil of 600cubic feet has to be excavated by hydraulic excavator of bucket

capacity 9.2 cft and excavated soil is carried to some distance and dumped by a tractor

whose truck capacity is 55 cft. The activity is captured by video and durations for

each tasks for multiple cycles are noted. The best fitting curve is obtained from each

task duration points and that distribution is inserted into model using ACD elements

in Microsoft Visio with EZStrobe.

Table 3 Activity Durations obtained at different locations

Duration

in minute Distribution

Tasks/Durations D1 D2 D3 D4 D5 D6

Excavate 0.175 0.16 0.151667 0.141 0.155 0.1473 Nor(0.16,0.012)

Swing loaded 0.084 0.085 0.092333 0.0843 0.085 0.0843 Pert(.0835,.085,.1)

Dump into tractor 0.077 0.07 0.079333 0.0813 0.09 0.0953 Nor(0.01,0.082)

Swing empty 0.085 0.095 0.083 0.0875 0.085 0.0812 Tri(0.08,.083,.098)

Haul to dumping

site

2.183 2.192 2.15 2.1583 2.267 2.095 Normal(2.17,0.056)

Align in position 0.226 0.248 0.223167 0.1857 0.2 0.2045 Normal(.14,.0.022)

Dump soil 0.85 0.927 0.981667 0.8833 0.893 0.9293 Normal(.91,.045)

Return to site 2.078 2.1 2.126667 2.0833 2.017 2.0783 Normal(2.1,0.04)


In the similar manner, activity cycle diagram for each

is created in Ezstrobe and through simulation durations for all the sub tasks and tasks

of those activites are determined.

For an idea, ACD of Earth work excavation whic

in figure 9.

Cost: On comparison from Table 1and 2

polystyrene panels (Rs.4, 32,088.00)is about 16% less than cost of the same when

using the conventional method of construction us

(Rs.5,83,859.00) for a single

about 35.7% in the total cost of materials, labor and equipment using cast in

concrete panels with EPS core and shear connectors was estimated for the project

Figure 10 Material cost c

• Duration: The time ta

technology is much less than RCC which has been analyzed through simu

EZ-Strobe, table 4.

0200004000060000

RCC with brick infill

Rupee

s



Figure 9 ACD for Earthwork

In the similar manner, activity cycle diagram for each of the construction activities


of those activites are determined.

For an idea, ACD of Earth work excavation which was made in Ezstrobe is shown

On comparison from Table 1and 2, the material cost when using the expanded


the conventional method of construction using RCC frame with brick infill

83,859.00) for a single–storey residential dwelling. An overall reduction of

35.7% in the total cost of materials, labor and equipment using cast in

concrete panels with EPS core and shear connectors was estimated for the project

Material cost comparison bar chart between Schnell and RCC Building

The time taken by each activity in Schnell Concrewall construction

technology is much less than RCC which has been analyzed through simu

RCC with brick infill Schnell with EPS panels

[email protected]

of the construction activities


n Ezstrobe is shown

cost when using the expanded


frame with brick infill

storey residential dwelling. An overall reduction of

35.7% in the total cost of materials, labor and equipment using cast in-situ

concrete panels with EPS core and shear connectors was estimated for the project.

omparison bar chart between Schnell and RCC Building

Concrewall construction

technology is much less than RCC which has been analyzed through simulation using




Table 4 Duration analysis for both Schnell and RCC structure

Schnell Concrewall house RCC Structure

S.No Activity Duration(hours) Activity Duration(Hours)

A1 Excavation 1.01 Excavation 10.4

A2

Reinforcement in

supporting

beams

8 Reinforcement up to

plinth level 3.7

A3 Slab foundation

casting 15

Concrete casting up

to plinth level 32

A4 Wall panel

erection 19.6 Plinth beam 23.3

A5

Roof panel

erection

including stairs

9 column raising to

Slab reinforcement 83

A6 Shotcreting 16.05 Slab casting 10

A7 Slab/Roof

casting 17.1 Brick wall 52

A8 Electrical

fixtures 0.67 Electrical fixtures 1.57

Figure 11 Durations for each activity in construction system

• Productivity:

The labors working under Schnell panel system are more productive because of

the simplicity of the construction technology.

Productivity = Quantity executed/Time taken to execute

Figure 12 Bar chart showing the productivity analysis

1.01 8 15 19.6 9 16.05 17.1 0.670

10

20

30

Schnell house Activity

durations

Activities

Du

rati

on

in

ho

urs

10.4 3.7

32 23.3

83

10

52

1.57

0

50

100

RCC activity durations

Activities

Du

rati

on

in

ho

urs

66

52

10

25

156

0

20

40

60

80

Walls Roof Electrical fixtures

Productivity rate for schnell(per.hr)

Productivity rate for RCC(per.hr)

Qu

an

tity

exe

cute

d

pe

r h

ou

r



5. CONCLUSION

The study indicates that expanded polystyrene wall and slab panels are cost effective

and efficient enough as a construction technology to be used as a replacement for the

traditional RCC frame with brick infill buildings. A time saving of 50% and cost

saving of 30% though labor, transport and hiring of construction equipment and

formwork, are being achieved. Use of expanded polystyrene panels also conserves the

environment by saving on the energy spent in construction, reducing visual intrusion

due to construction activities, reducing damage to landscapes.

REFERENCES

[1] Concrewall building system-The innovative Concrewall building [M2] system,

www.cbs-ibs.com.

[2] Rohit Raj, Manoj Kumar Nayak, Md Asif Akbari and P. Saha, Prospects of

Expanded Polystyrene Sheet as Green Building Material, International Journal of

Civil Engineering Research 5(2) 2014.

[3] Marvin E.Mundel, David L. Danner, Motion and Time study improving

productivity, Prentice Hall India, 1948.

[4] Government of India, CPWD (2013), Analysis of Rates for Delhi, Volume1.

[5] C.Freeda Christy, R.Mercy Shanthi, D.Tensing, Bond Strength of The Brick

Masonry. International Journal of Civil Engineering and Technology, 3(2), 2012,

pp.380–386.

[6] Ghassan Subhi Jameel, Study The Effect of Addition of Wast Plastic On

Compressive and Tensile Strengths of Structural Lightweight Concrete

Containing Broken Bricks As Acoarse Aggregate. International Journal of Civil

Engineering and Technology, 4(2), 2013, pp.415–432.

[7] Brian Jacks Odero, R. N. Mutuku and C. K. Kabubo, Mechanical Characteristics

of Normal Concrete Partially Replaced with Crushed Clay Bricks. International

Journal of Civil Engineering and Technology, 6(1), 2015, pp.62–75.

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A COMPARATIVE STUDY OF CONSTRUCTION USING · PDF fileInternational Journal of Civil Engineering and Technology (IJCIET ... A COMPARATIVE STUDY OF CONSTRUCTION USING ... reinforced