TRANSFER OF THE IMS BUILDING TECHNOLOGY INTO DEVELOPING COUNTRIES

Transcription

1 TRANSFER OF THE IMS BUILDING TECHNOLOGY INTO DEVELOPING COUNTRIES Radovan Dimitrijevic, Institute for Testing of Materials, Yugoslavia Sladjan Jovancov, Institute for Testing of Materials, Yugoslavia KEY WORDS Transfer, building technology, designing, engineering, consulting Over the past four decades, the IMS Institute has developed and created a huge base of knowledge on housing, defined through software, studies, publications, designs and experience of the personnel. This data base can be used very efficiently to choose and form for every user the adequate - specific IMS building technology which will completely suit the general concepts of the IMS system, and at the same time be adapted to the possibilities of the user regarding the local resources and manpower, as well as the geographic, climatic, seismic and other conditions. These parameters serve as the foundation for defining different architectural - constructive solutions of structures, adequate degree of prefabrication and organization of production of elements in factory conditions. Introduction-peneral features of the IMS building technolopy The original concept of the IMS building technology consists of several basic features, namely: - the load-bearing structure is represented by concrete skeleton strutted by shear walls, which offers universal possibilities of applying the structure in highly seismic zones, that is, in zones with the strongest winds; - the joints between the elements of the load-bearing structure are implemented by prestressing with the use of adequate equipment; - the selected IMS structural system has universal application for all types of buildings in housing, which results in maximum flexibility offering architects a wide range of possibilities and liberties as regards functional and architectural shaping of buildings with a very small number of restrictions; - relatively small number of standard structural elements, together with a simple way of production - prefabrication in large series and in factory conditions (either in workshops or in outdoor plants), enable the construction of unique architectural structures; - high-quality materials - concrete and steel - are applied, as this is a precondition for stability and durability of the load-bearing structure, as well as for low operating costs, while the quantity of the applied materials is rather small; - it is possible to apply secondary systems fiom "open prefabrication" (elements which are also used in other building systems), as well as local materials and products, with the participation of the local manpower; - there is a wide range of possible structural spans, which means that the IMS skeleton structure can be used to form very diversified structures, both regarding the foundation and the volume; - efficient organization of designing by using catalogues of structural elements, with computer data processing, enables very fast estimation of different variant solutions; - quality control systems are applied in designing, production and assembly of elements.

2 L Side elevation of the IMS Building in Angola Floor plan, IMS Building in Angola Illdices of manpower input in IMS framework construction per m2 total area of objects (Including columns, floor slabs, shear walls and staircases) Cost indices per m2 of apartment space for different building systems IMS system consumption of materials and manpower as a functlon of span step K +' 9 9 9lc $40 $uj so so ro cp %' I0 9 P to 0 C A Conventional building B Tunnel shuttering system C IMS system Material Manpower Total,3$$ PPP level x x x x x X X X X X X X X g$'$'qq B3k I II 111 I d = 22 cm Manpower II d = 30 cm Reinforcement Ill d = 36 cm Concrete

3 Elaboration of feasibility study The above-presented indices related to the IMS building technology enable very cheap construction of all kinds of structures in various conditions, so it is logical that the IMS technology has become extremely interesting for developing countries. From the aspect of political, legal, social, economic, technological, geographic and other potentials of individual developing countries, with the focus on the data related to certain regions and towns (population, industrialization level, number of employed persons, trends of further development, and the like), the IMS Institute - as the bearer of the building technology - offers services for the elaboration of feasibility studies, at the request of and in cooperation with the potential investor. The aim of such studies is to justify the choice of a certain IMS building technology from the viewpoint of the investor's gain - profit, and at the same time to support the performance of the selected technology for the given project (one or more structures). The feasibility study comprises the following: - general data related to the project - building (purpose, location, number of storeys, area of construction, and the like), - schematic structure of the building by storeys, - estimated value of the project (value of investment and value of the expected gain - profit, possibility of selling the structure for a certain price at the local market), - sale and marketing with marketing alternatives, - potential buyers and creditors, - financial analysis with the CASH FLOW STATEMENT, in dependence on the term for concluding the works, the amount of the loan and the term for repayment, initial investment and other necessary parameters. Defining the conditions for transfer of the IMS building technoiogv (~roject task) With the aim of achieving the highest degree of quality and efficiency in the transfer of the IMS building technology to an individual user, it is necessary to defme the conditions and requirements in such a way that the IMS technology is fully adapted to the wishes and potentials of the user. To this point, the IMS Institute sends to each user an INQUIRY FORM. When the user fills in this form, it is used as the foundation for elaborating a very precise project task. That is why its content can be considered to be the very PROJECT TASK. Since the transfer of the IMS building technology can conditionally be divided into two parts (structures and production plant), the content of the INQUIRY FORM - that is, the PROJECT TASK - regards the following two groups of data: 1. Data on the buildings for which the given technology is designed, and 2. Data on the plant - factory for the production of structural elements for the buildings mentioned under The group of data for buildings to be constructed in the IMS technology comprises: 1.1. General data on buildings, including: - Town-planning conditions (whether or not they exist), - Type and purpose of the building (residential, office, industrial, combined, etc.), - Maximum number of storeys, - Height of storeys, - Necessary annual gross floor area of the buildings, - Data on face walls, lift elements and kitchen or bathroom walls or units (if they are precast), - Other data (if there are any) Data on climatic conditions and soil conditions necessary for the designing of buildings, including: - Air temperature (the lowest daily temperature, the lowest average five-day temperature), - Snow load,

4 - Wind load, - Freezing depth, - Seismic rating of the area by Mercalli scale, - Geological composition of soil, - Load-bearing capacity of soil, - Level of possible sub-soil water, and - Other data (if there are any). 2. The group of data for the plant in which the elements are to be manufactured comprises: 2.1. Data on the production programme in the plant, including: - Range of produced elements - degree of prefabrication, - Capacity (scope) of production (sq. m.1 year or apartments 1 year), - Number of workdays per year, - Number of workdays per week, - Number of shifts per day, - Standards used for quality control, - Other data (if there are any) Data for the plant - factory: - General description of the factory, if an already existing one is used for introducing technological lines of the IMS technology; or else, the description of the locality for the construction of a new plant, - Description of the locality and its surroundings, with traffic routes and infrastructure, - Layout of the site in 1 :500 or 1 : 1000 scale, and - Town-planning conditions (whether or not they exist) Data on climatic conditions and soil conditions necessary for the designing of the factory: - Same data are given here as for the construction of the buildings (under 1.2.), but with respect to the locality of the factory Data on energy resources, raw materials and semi-finished manufactures, including: - Quality and composition of all input raw materials for the production of elements, and distance to the field, - Possibility of supplying water, water vapour, compressed air and electric power Data on storage, including: - Storage of raw materials and semi-finished manufactures for a certain period, - Storage of finished elements for a certain period, and - Waste dumping place Other data, namely: - Data on special conditions of the living environment, - Possibility of other alternative production programmes within the factory, and - Strategic conditions to be fulfilled by the project. On the basis of the PROJECT TASK defined in such a way, a specific IMS building technology is formed, so that it is adapted to all the afore-mentioned data and requirements supplied by the user. Transfer of the IMS building technolopy The IMS Institute implements the transfer of the adequate building technology for individual users through the following forms of activities: A. Designing (service and product) B. Engineering (product) C. Consulting (service)

5 Activities in the field of designing are carried out with the aim of elaborating technical documentation divided into five basic groups, namely: A. 1. Documentation of the IMS building technology, A.2. Documentation for the production of elements, A.3. Documentation for the construction of buildings, A.4. Documentation of the equipment for the production of elements, and A.5. Documentation of the equipment for the assembly of elements. A. 1. Documentation of the IMS building technology includes: - Technical description of the IMS building technology with the instructions for designing, production and assembly, - Statical and other computations for elements, - Catalogue of elements (plans for formwork, reinforcement and details of joints), and - Standards for materials and manpower for the production and assembly of elements of the IMS building technology. A.2. Documentation for the production of elements includes: - Technologycal design of the process of production of elements in the factory, - Main design of the factory for the production of elements, - Project for concrete, - Design for the production quality control, and - Project for the occupational safety in the factory. In the case when the user designs and builds the plant - factory in his own organization, the IMS Institute gives him the input data (level of the project task) on the basis of the required performances from the technologycal design of the production process (layout of the equipment, connections, necessary installed power of the equipment, necessary quantities of water, vapour, compressed air, and many others) for the main design of the plant - factory. A.3. Documentation for the construction of the first buildings - prototypes includes: - Main design of the building, - Main design for the implementation of the structure. A.4. Documentation of the equipment for the production of elements includes: a) Mechanical design of the specific IMS equipment for production (moulds, equipment for transporting elements, laboratories, etc.) with: - Assembly and workshop drawings necessary for the production of the equipment, and - Technical descriptions, specifications of the equipment and lists of spare parts, instructions for handling and maintenance, b) Performances of other equipment for production - transportation means, individual machines and tools, and the like. Depending on the supply, transportation, storage and similar conditions, the user can purchase a part of the equipment at the local market, in agreement with the IMS Institute, and in line with the requirements and performance of the equipment from the technical design. To this regard, the abovecited documentation is unified within the framework of the production departments of the factory. A.5. Documentation of the equipment for the assembly of elements includes: a) Mechanical design of the specific IMS equipment for assembly (equipment for supporting the elements, prestressing equipment, equipment for calibration, etc.) with:

6 - Assembly and workshop drawings necessary for the production of the equipment, and - Technical descriptions, specifications of the equipment and lists of spare parts, instructions for handling and maintenance, b) Performances of other equipment for assembly - external transportation, transportation means at the building site, and the like. Similar as in the case of the equipment for production, this documentation is unified as regards the checking of the required technical specifications of the equipment, and in line with the dimensions and weight of the elements, the position during transportation (horizontal, vertical or slanting), the place of the given element within the building's structure, etc. B. Engineering The activities related to the engineering works are divided into three basic groups, according to the stages within the implementation of the IMS building technology transfer. These three groups are: B. 1. Production and purchase of the equipment, B.2. Construction of the factory for the production of elements, and B.3. Construction of buildings - prototypes. B. 1. Production and purchase of the equipment: - Activities in the stage of the production and purchase of the equipment for the production of elements of the specific IMS equipment and other equipment, and - Activities in the stage of the production and purchase of the equipment for the assembly of elements of the specific IMS equipment and other equipment. The activities in these stages include: collecting tenders offered by equipment manufacturers, signing of contracts, control of the equipment production, final control and reception of the equipment, delivery of equipment and complaints within the guarantee period. B.2. Construction of the factory for the production of elements: The IMS Institute can organize the construction of the plant - factory in line with the turn-key principle, but the Institute's involvement usually comprises only the following: - Activities in the form of expert monitoring and technical assistance in the stage of the construction of the workshop with all other secondary facilities of the factory complex, - Activities in the form of expert monitoring and technical assistance in the stage of equipment assembly in the factory, and - Activities in the stage of pilot production and of demonstrating the designed capacity of the factory, with the delivery of the factory to the user and complaints within the guarantee period. Other activities in these stages include: collecting tenders offered by sub-contractors, signing of contracts, quality control, and the like. B.3. Construction of buildings: Same as for the construction of the factory, the IMS Institute can organize the construction of the first buildings in line with the turn-key principle, but the Institute's involvement usually includes only the following: - Activities in the form of expert monitoring and technical assistance in the stage of the construction of buildings (traditional and precast parts with all instaliation, construction and finishing works), and - Activities concerning the delivery of the building to the user and complaints within the guarantee period.

7 Activities in these stages include: collecting tenders offered by sub-contractors, signing of contracts, quality control, and the like. Consulting services offered by the IMS Institute to the user through the transfer of the IMS building technology are implemented in the following forms: C. 1. Training of personnel, and C.2. Technical assistance. Both kinds of services are carried out parallelly with the engineering activities (B.2. stage of the construction of the factory and B.3. stage of the construction of the building). Their aim is to use: C.1. Training of personnel - for qualifying the user's staff to carry out the following specialized jobs: - designing of structures in the IMS building technology, - regular, successful and long-term utilization of the factory (through complete mastery of the production process and the handling of the production equipment), - regular, successful and long-term utilization of the equipment onto the structure (both assembly and prestressing equipment), and C.2. Technical assistance - for ensuring the regularity of the execution of works in all the stages of the implementation of the IMS building technology transfer, in line with the design documentation, with the introduction of the quality control system. The following Figure is a schematic representation of the IMS building technology transfer, while the numerical marks correspond to the respective marks of the activities used in the above text. I:-- TECHNICAL, DOCUMENTATION I I1 IMS BlJllDlNG TECHNOLOGY I TRANSFER OF THE IMS BUILDING TECHNOLOGY I v I DESING CONTROL I C CONSULTING i ('A1'.4LllC;!rE OH f::.t:men'i'; ~FO1tMICOlfk t!i.:l!cf'oj?('emb:?,t. JOLNTS) I.z'l';~,N[~,4R11? FOlt MA'1'I':KIAL:~ ANli h~l:lnl'i?ffi.:r PRO~DUCTIOEI OF ELEMENTS CONSTRUCTION OF THE BUILDING I

8 Examples for impleme~tion Over the past three decades, a series of IMS building technology transfers have been implemented. In the former Socialist Federal Republic of Yugoslavia, this building technology was adopted by numerous construction companies in the republics of Serbia (12), Bosnia-Herzegovina (4) and Croatia (I), and they annually constructed 5-10 thousand apartments with the average floor area of about 60 m2. The exact number depended on the available financial resources, while the installed capacity of the factories was about 12,000 apartments per year. It is also important to mention that the transfer of the IMS building technology was successfully implemented into a series of other countries, of which the following should be emphasized. In Cuba, the first plant for the production of elements of the IMS skeleton building system was implemented as in situ production for the construction of the first residential buildings (1968) in Havana. After that, several factories were constructed, each with the annual capacity of 1,500 apartments. The involvement of the IMS Institute for the construction of the first three factories ( ) - in San Jose, Santiago de Cuba and Cien Fuegos - consisted in elaborating complete technical documentation for the factories, catalogues of elements and of the first buildings, with technical assistance and training of personnel, while the local partner supplied material and manpower for the construction of the plants and of the buildings. In Egypt, near the capital of Cairo, a plant was constructed in 1982 at an exposed situation just next to the building site, with the capacity of 1,000 low-cost standard apartments. The concept of the IMS technology transfer was similar to the one implemented in Cuba. It is, however, interesting that within the framework of consulting - technical assistance and training of personnel - the total of 5 experts of the IMS Institute were engaged, with the overall duration of 12 workerlmonths. It should also be underlined that the cost per one square meter of dwelling space amounted to 83 US$ (in 1983), out of which the expenses for depreciation of the equipment, know-how and consulting of the Institute for the first 1,000 apartments covered 26 US$/m2. In Ethiopia (Addis Ababa), a factory of the IMS building technology was erected in 1983, with the purpose of constructing residential and office buildings, and the annual capacity of 50,000 sqaure meter. Transfer procedure similar to the above-mentioned ones was applied, so that the local partner constructed the factory and the buildings with technical management by the IMS Institute. The engagement within the framework of technical assistance in Ethiopia was 10 workerlmonths, carried out by 5 experts from Yugoslavia. In Nevinnomyskk (Russia), a factory erected in 1989 has the annual capacity of 30,000 square meter of dwelling space, in line with the turn-key principle of technology transfer. The contractor of works for the construction of this factory was the Krajina company of Banja Luka. The transfer of the IMS building technology for a factory in Moscow (Russia) and another one in Manilla (Philippines) is underway. Conclusion The above-mentioned examples prove that contemporary building technologies - with the application of highquality materials for the load-bearing structure and of local construction materials for other parts of the building, as well as the use of local manpower - can give successful results in housing construction, for resolving vital living problems of the population in developing countries. This goes against a hypothesis saying that contemporary construction materials (prestressed concrete) and sophisticated building technologies (use of information software for designing, quality control, etc.) are neither economical nor applicable for developing countries, that they are expensive, inefficient, and the like. Nevertheless, the only solution to the exceptional challenges currently faced by the developing countries is the correct application of the selected prefabrication system - that is, industrialization of housing.

9 References Dimitrijevic, Radovan "IMS building technology", Belgrade, Dirnitrijevic, Radovan et al., "IMS Institute", Belgrade, Djordje, Zrnic "Designing a factory", Belgrade, Group of authors, "Catalogue of the IMS building system", Belgrade, Group of authors, "Standards of the IMS building system", Belgrade, 1984.