Building the Future With Innovation DfMA- DESIGN for MANUFACTURING AND ASSEMBLY

Transcription

1 SEMBCORP EOSM PTE LTD Building the Future With Innovation DfMA- DESIGN for MANUFACTURING AND ASSEMBLY 2 February 2015

2 SEMBCORP EOSM a SUBSIDARY OF SEMBCORP INDUSTRIES Temasek Holdings Sembcorp Industries (SCI) Sembcorp Design & Construction (SDC) Sembcorp Architects & Engineers (SCAE) Sembcorp EOSM Sembcorp EOSM (Malaysia) Sembcorp EOSM (India)

3 SEMBCORP EOSM a SUBSIDARY OF SEMBCORP INDUSTRIES USING THE TECHNOLOGY OF TOMORROW TO ENHANCE PRODUCTIVITY THROUGH ECOLOGICAL OFFSITE MANUFACTURING Temasek Holdings Sembcorp Industries (SCI) Sembcorp Design & Construction (SDC) Sembcorp Architects & Engineers (SCAE) Sembcorp EOSM Sembcorp EOSM (Malaysia) Sembcorp EOSM (India) The basic principles behind the OSM approach include prefabrication, preassembly, subassembly, etc. and these are terms frequently used in OSM. An OSM product is a complex system, which is made up of many sub-assemblies of each part (sub-systems) whereby their assembly constitutes a new product. Through product modularization, the manufacturer can create many products by assembling different sub-assemblies within a short product development lead time. WE can also produced as a complete volumetric unit, usually fully fitted-out and tested before it is installed.

4 Sembcorp Design and Construction Group MD Business Development Engineering Services Construction Services Business Support and Resourcing Services Materials : Sembcorp EOSM Contract & Procurement Business Development Defence Group Commercial Group Defence Group Commercial Group Modular Construction Land Reclamation Sembcorp EOSM SIngapore Sembcorp EOSM Malaysia Interco Group Interco Group Underground Tunneling Sembcorp EOSM Others Utilities Infrastructures for Water, Power, Energy from Waste Sembcorp Industries

5 The basic principles behind the OSM approach include prefabrication, preassembly, subassembly, etc. and these are terms frequently used in OSM. An OSM product is a complex system, which is made up of many sub-assemblies of each part (sub-systems) whereby their assembly constitutes a new product. Through product modularization, the manufacturer can create many products by assembling different subassemblies within a short product development lead time. WE can also produced as a complete volumetric unit, usually fully fitted-out and tested before it is installed. Modular volumetric building Modular Hybridvolumetric building Modular system building Modular elemental building Volumetric off-site fabrication Non-volumetric off-site fabrication Component subassembly Off-site manufactured -Volumetric Off-site manufactured - Hybrid Off-site manufactured - Panelised

6 SEMBCORP EOSM a SUBSIDARY OF SEMBCORP INDUSTRIES USING THE TECHNOLOGY OF TOMORROW TO ENHANCE PRODUCTIVITY THROUGH ECOLOGICAL OFFSITE MANUFACTURING Our company is in the business of research and developing, design and engineering for the NEW GENERATION CONCRETE using different synthetic and steel fibre and fly ash. With the Ultra High Performance Concrete, we are able to apply into building products for the offsite Manufacturing We seek to enhance construction Productivity through Design, Engineered and Manufacturing of ecological products in 2D or 3D offering Green, lighter, high performance, thermal insulated and fire rating, acoustic. 1 st Vertical- Prefab Solutions and Products ECC-Crete wall and facade, epods, eriser, emodule, precast,etc 2nd Vertical- Prefab Solutions and Products for Affordable Housing (co-developing model with developers, Government agencies, contractors) 3rd Vertical- ECC-Crete AAC ECC-Crete secondary roof ECC-Crete Mix W, F

7 SEOSM Business Unit SHELF PRODUCTS SPECIALIST PRODUCTS SPECIAL PROJECTS 1. AAC -eblock 2. AAC epanel 3. ECC-Crete Mix 4. epaver 5. Secondary Roof Slabs 6. Left-in formwork 7. ECC-Crete fiber sheet 1. emodule - PPVC 2. epod PBU 3. ECC-Crete Wall 4. efacade 5. Precast Items SEOSM s technical crew & mobile factory with JV partners

8 Presentation: 1. Technical capability 2. Design for manufacturing and Assembly 3. flexibility

9 Plug & Play for DfMA

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14 Putting all together emodule- factory prefinished

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16 2. Design for Manufacturing and Assembly

17 1. Technical capability

18 Design for manufacturing and assembly : a key lever for improving the productivity and performance of construction industry. Plug & Play project an entirely new paradigm in the construction sector the next paradigm, a mindset within which you can solve the problems and overcome the barriers the building industry obviously could not solve within the old paradigm.

19 The vision in the Plug&Play project is that in the future, the largest part of the built environment (new or existing) will rely on the concept of open building system characterised by the following properties: An entire building can be assembled from industrial parts or subsystems, and all (or at least most) of the building can be dismembered (with any part having the potential to be assembled elsewhere) according to a well-defined contract (set of formalised rules & constraints); Any individual industrial part can be transported and functionally bound to the system without cutting, milling or any other transformation, provided that it comes with the right interfaces compliant with the rules & constraints put on the parts. At the extreme, the system should be designed for self-assembly;

20 1. Reduce the total number of parts. The reduction of the number of parts in a product is probably the best opportunity for reducing manufacturing costs. Less parts implies less purchases, inventory, handling, processing time, development time, equipment, engineering time, assembly difficulty, service inspection, testing, etc. In general, it reduces the level of intensity of all activities related to the product during its entire life. Some approaches to partcount reduction are based on the use of one-piece structures and selection of manufacturing processes such as molding, extrusion, among others.

21 2. Develop a modular design. The use of modules in product design simplifies manufacturing activities such as inspection, testing, assembly, purchasing, redesign, maintenance, service, and so on. One reason is that modules add versatility to product update in the redesign process, help run tests before the final assembly is put together, and allow the use of standard components to minimize product variations. However, the connection can be a limiting factor when applying this rule.

22 3. Use of standard components. Standard components are less expensive than custom-made items. The high availability of these components reduces product lead times. Also, their reliability factors are well ascertained. Furthermore, the use of standard components refers to the production pressure to the supplier, relieving in part the manufacture s concern of meeting production schedules.

23 Ecological Offsite Manufacturing 1 st Vertical Building the Future With Innovation innovation is not simply the development of new products but also the transformation of the construction process, both in what we build and how we build. We seek to collaborate in new ways, with new business models, new delivery mechanisms and most importantly, new ways of working with clients in order to deliver their ambitions and make them more successful. Four main categories of offsite construction:

24 Putting all together- PLUG & PLAY CONCEPT ECC + AAC ECC-Crete wall epod ( BIP approval) ECC-Crete efacade emodule (BIP approved) ECC-Crete eriser ECC-Crete Integrated Floor For Building Construction

25 Putting all together + structural steel + architectural finishes + doors/windows + mep + others

26 Putting all together ECC-CRETE WALL

27 Putting all together ECC-CRETE eblock and epanels

28 Putting all together ECC-CRETE FACADE

29 Putting all together TECHNICAL- DATA- ECC-CRETE FACADE CW

30 Putting all together TECHNICAL- DATA- ECC-CRETE FAÇ ADE CW

31 Putting all together ECC-CRETE epod

32 Putting all together epod epods which are built and completed totally in factory conditions. The shells is constructed of ECC or engineered cement composites The pods in the patented Lightweight Concrete provide good fire and acoustic rating possibilities, and are completed with all accessories as per client specification. All epods are built in accordance with the current regulations in the countries of destination to ensure that every detail is compliant, especially plumbing and electrical systems. The finishing stage of the prefabricated shell begins with installation of plumbing and electrical systems. We then move on to tiling, sanitary and bathroom accessories followed by final testing, cleaning and quality control, so that the prefabricated bathroom is ready for delivery and connection to site services.

33 Putting all together epod epod With finishes MEP services Modular bathroom 2600 X 1300 mm Using ECC-Crete wall of 70mm thick and ECC-Crete base with waterproofing Complete with MEP and finishes Weight : estimate 2.3 tonne

34 Putting all together epod modular bathroom design and options of finishes and fixtures

35 Putting all together epod Manufacturing Process in Factory:

36 Putting all together epod These lean manufacturing methods reduce waste & increases productivity as epods can move down the production line without stopping or waiting. Phase 1 Wall & Ceiling Panels Assembled w Subflooring Phase 2 Rough Plumbing & Electrical Work Performed Phase 3 Cutouts Phase 4 Tape & Spackle, Waterproofing, Priming, & Tiling Performed Phase 5 All Fixtures, Accessories & Door/Hardware Installed Phase 6 Final Paint Coat & Grouting Applied, POD Wrapped For Shipment

37 Putting all together epod

38 Putting all together emodule emodule

39 Putting all together emodule

40 Putting all together emodule

41 Putting all together emodule The emodule are manufactured off-site, it can be completed with internal fixtures and fittings before being delivered to the construction site. Temporary protection is maintained until the exterior cladding is erected. Element Steel frame / truss Infill wall Floor MEP Wall / floor finishing Doors / windows Fitment Description Structural steelwork of rolled sections or hollow sections with welded connections to form a box shape module. ECC-Crete Wall is used as non-load bearing wall for the external or internal wall. Either composite or precast slab placed in a structural steel framing of the volumetric module. Can be chased or pre-run. Can be customized and built in factory. Can be factory mounted. Can be factory mounted.

42 Putting all together emodule

43 Putting all together emodule

44 Putting all together emodule PATENT PENDING

45 Putting all together emodule emodule SYSTEM 1- beam/column Room mdoule complete with steel framing PATENT PENDING

46 Putting all together emodule emodule SYSTEM 1- beam/column Room module complete with inbuilt steel framing PATENT PENDING

47 Putting all together emodule Spatial modular chasis comprising main structural framing with mep service Room modules with wall, windows/doors, internal partition, floor finishing and structural framing with mep service emodule SYSTEM 3- ROOM MODULE +steel column + FLOOR/SPATIAL MODULE

48 Putting all together emodule emodule SYSTEM 3- ROOM MODULE +steel column + FLOOR/SPATIAL MODULE

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52 Putting all together emodule

53 Putting all together emodule

54 Putting all together emodule Element Steel frame / truss Infill wall Floor MEP Wall / floor finishing Doors / windows Fitment Description Structural steelwork of rolled sections or hollow sections with welded connections to form a box shape module. ECC-Crete Wall is used as nonload bearing wall for the external or internal wall. Either composite or precast slab placed in a structural steel framing of the volumetric module. Can be chased or pre-run. Can be customized and built in factory. Can be factory mounted. Can be factory mounted. Hybrid of steel and concrete slab with ECC-CRETE WALL for emodule LIGHTWEIGHT AND HIGH PERFORMANCE MATERIAL- ECC-CRETE SUSTAINABLE AND GREEN REDUCE CARBON FOOTPRINT THERMAL INSULATION ENERGY CONSERVATION ECOLOGICAL MODULE OFFSITE MANUFACTURING

55 emodule - Manufacturing steps 1. Erect steel work 3. Erecting the large ECC-Crete panel 2. Fire protection of steel beam 4. Ready to receive precast slab

56 Putting all together emodule steel work top brace and siffener part of wall panel Steel column and beam part of base large ECC-Crete panel with steel stiffener and brace large ECC-Crete panel with steel stiffener and top brace ECC SKIN OVER STEEL COLUMN AND BEAM

57 Putting all together emodule IN OUT ECC-Crete large wall panel production Steel work and finishing and fitout production 1. Assembling of steel work for module 2. Casting and mounting of ECC-Crete large panel to steel work for module 3. Finishing and mep works incl fit out to module

58 Putting all together emodule

59 Putting all together emodule

60 Putting all together emodule

61 Putting all together emodule

62 Putting all together emodule

63 Putting all together emodule-liftcore LIFTCCORE

64 Putting all together emodule-staircase STAIRCASE

65 Putting all together emodule-staircase STAIRCASE

66 Putting all together eriser

67 Putting all together eriser ECC-Crete wall uses as customised large size lightweight Precast sandwich panels for volumetric construction of shafts. The panels are prefabricated of hybrid of Engineered Cement Composites with autoclaved aerated concrete (AAC) thickness 50,75 and 100 mm) for use as non load bearing wall ). The panels are provided with a reinforcement (for non structural purposes) for handling during transport. LIGHTWEIGHT AND HIGH PERFORMANCE MATERIAL- ECC-CRETE SUSTAINABLE AND GREEN REDUCE CARBON FOOTPRINT THERMAL INSULATION ENERGY CONSERVATION ECOLOGICAL MODULE OFFSITE MANUFACTURING Applications lighweight precast volumetric elements with doors, firestop, water barriers options PPVC for shafts

68 Putting all together MODULAR FLOOR Structural double Tee Slab with cavity use as vent duct and mep run

69 Putting all together-integrating INTEGRATING THE DIFFERENT DfMA PRODUCTS INTO PROJECTS 01 Twin wall 02- slab 03 ECC-Crete wall 04- ECC-Crete Façade 05- ECC-Crete epod 06-Stair 07- liftcore 08-eRisers

70 Putting all together-integrating INTEGRATING THE DIFFERENT DfMA PRODUCTS INTO PROJECTS

71 Putting all together-integrating INTEGRATING THE DIFFERENT DfMA PRODUCTS INTO PROJECTS

72 Putting all together + structural steel + architectural finishes + doors/windows + mep + others

73 3. flexibility- Easily removed or upgraded Can be transported as a module

74 TECHNICAL- DATA- ECC Sembcorp EOSM Research and Developments on ECC-Crete RETURN TO

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76 CONSTRUCTION INDUSTRY ON PRODUCTIVITY -2 nd generation precast OUR SOLUTION- ECC-CRETE TECHNOLOGIES LIGHTWEIGHT AND HIGH PERFORMANCE MATERIAL- ECC-CRETE SUSTAINABLE AND GREEN REDUCE CARBON FOOTPRINT THERMAL INSULATION ENERGY CONSERVATION ECOLOGICAL MODULE OFFSITE MANUFACTURING

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78 TECHNICAL- DATA- ECC Sembcorp EOSM Research and Developments on ECC-Crete, epodand emod

79 ECC-Crete Panel (flexural strength test result)

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81 PRODUCT- DATA- ECC-CRETE WALL

82 PRODUCT- DATA- ECC-CRETE ECC-CRETE (passed 4-hour fire test on 3m x 3m sandwich wall panel)

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84 A) General Introduction of proposed system: Crack Line:

85 PRODUCT- DATA- ECC-CRETE

86 PRODUCT- DATA- ECC-CRETE STC STC for ECC-Crete with flyash block infill

87 Thank You