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The Use of Pre-Engineered Building System in The Use of Pre-Engineered Building System in Mining Industries; the Implementation of Value Mining Industries; the Implementation of Value Engineering Concept in Optimizing Project Cost Engineering Concept in Optimizing Project Cost (Case Study: Fire Station and Emergency Clinic (Case Study: Fire Station and Emergency Clinic

Project)Project)

11stst MICCE MICCE

Makassar, IndonesiaMakassar, Indonesia

March 2010March 2010

Presented byPresented byIr. Habibie Razak, IPIr. Habibie Razak, IP

Ir. Hajar AswadIr. Hajar Aswad

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AGENDAAGENDA Value Engineering in Construction Value Engineering in Construction

Project Project

Pre-Engineered Building System, an Pre-Engineered Building System, an Alternative Design to Implement Value Alternative Design to Implement Value Engineering ConceptEngineering Concept

Use of PEB in Use of PEB in Mining Industries, Case Mining Industries, Case Study: Study: Fire Station and Emergency Clinic Fire Station and Emergency Clinic Building Project; the Implementation VE Building Project; the Implementation VE ConceptConcept

Lessons Learned and RecommendationLessons Learned and Recommendation

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Value Engineering in Construction Value Engineering in Construction ProjectProject

• VE is a systematic evaluation of a project design to obtain VE is a systematic evaluation of a project design to obtain the most value for every dollar of cost. By carefully the most value for every dollar of cost. By carefully investigating costs, availability of materials, construction investigating costs, availability of materials, construction methods, shipping costs or physical limitations, planning methods, shipping costs or physical limitations, planning and organizing, cost/benefit values, and similar cost and organizing, cost/benefit values, and similar cost influencing items, an improvement in the overall cost of a influencing items, an improvement in the overall cost of a project can be realized.project can be realized.

• 4 Fundamentals of VE4 Fundamentals of VE

Function = specific purpose or use intended for somethingFunction = specific purpose or use intended for something

Worth = least cost required to provide the functionWorth = least cost required to provide the function

Cost = total amount of money required to obtain and use Cost = total amount of money required to obtain and use the functionthe function

Value = worth = utilityValue = worth = utility

cost costcost cost

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Opportunity

for VE by the Contractor

Opportunity for VE by

the Architect or Engineer

Level of

Activity

TimeProject/Phase Start

Project/Phase Finish

Feasibility Study Phase

Design PhaseProcurement Phase

Construction PhaseStart-up

Phase

Operation & Maintenanc

e Phase

Opportunity for Value Engineering:Opportunity for Value Engineering:VE by the Architect or Engineer, VE by ContractorVE by the Architect or Engineer, VE by Contractor

Initiating Processe

s

Planning Processe

s

Controlling Processes

Closing Processe

s

Executing

Processes

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Methods of Value Engineering used by EngineersMethods of Value Engineering used by Engineers

Design concrete structures with as many Design concrete structures with as many duplicate members as is practical to allow the duplicate members as is practical to allow the reuse of forms without rebuildingreuse of forms without rebuilding

Confine design elements to modular material Confine design elements to modular material sizes where possiblesizes where possible

Simplify the design of the structure wherever Simplify the design of the structure wherever possible possible

Design for the use of cost-saving equipment and Design for the use of cost-saving equipment and methodsmethods

Eliminate unnecessary special construction Eliminate unnecessary special construction requirementsrequirements

Design to reduce the required labor to minimumDesign to reduce the required labor to minimum Specify a quality of workmanship that is Specify a quality of workmanship that is

consistent with the quality of the projectconsistent with the quality of the project

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Methods of Value Engineering used by Engineers Methods of Value Engineering used by Engineers (Continued)(Continued)

Furnish adequate foundation information Furnish adequate foundation information wherever possiblewherever possible

Refrain from requiring the contractor to assume Refrain from requiring the contractor to assume responsibility for information that should have responsibility for information that should have been furnished by the engineer, or for the been furnished by the engineer, or for the adequacy of the designadequacy of the design

Use local materials when they are satisfactoryUse local materials when they are satisfactory Write simple, straightforward specifications that Write simple, straightforward specifications that

state clearly what is expected of the contractor. state clearly what is expected of the contractor. Use standardized specifications that are familiar Use standardized specifications that are familiar to most contractors whenever possibleto most contractors whenever possible

Hold preconstruction conferences with Hold preconstruction conferences with contractors to eliminate any uncertainties and to contractors to eliminate any uncertainties and to reduce change orders resulting from reduce change orders resulting from misunderstandings to a minimummisunderstandings to a minimum

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Pre-Engineered Building System, an Pre-Engineered Building System, an Alternative Design to Implement Value Alternative Design to Implement Value

Engineering ConceptEngineering Concept In structural engineering, In structural engineering, pre engineered pre engineered

buildingsbuildings (PEBs) is constructed using a pre- (PEBs) is constructed using a pre-determined inventory of raw materials that can determined inventory of raw materials that can satisfy a wide range of structural and aesthetic satisfy a wide range of structural and aesthetic design requirement.design requirement.

The primary framing structure: build up of I shaped The primary framing structure: build up of I shaped members, often referred as I beams. members, often referred as I beams.

The I beams used are usually formed by welding The I beams used are usually formed by welding together steel plates to form the I section. The I together steel plates to form the I section. The I beams are then bolted together to form the entire beams are then bolted together to form the entire frame of the Pre-Engineered Building. frame of the Pre-Engineered Building.

Some manufactures taper the framing members Some manufactures taper the framing members (varying in web depth) according to the loadings (varying in web depth) according to the loadings with larger depths in the areas of highest stress.with larger depths in the areas of highest stress.

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Pre-Engineered Building System, an Pre-Engineered Building System, an Alternative Design to Implement Value Alternative Design to Implement Value

Engineering Concept (Continued)Engineering Concept (Continued) Basic Building Parameter of Pre-Engineered Basic Building Parameter of Pre-Engineered

BuildingBuilding

Building WidthBuilding Width

Building LengthBuilding Length

Building HeightBuilding Height

Roof SlopeRoof Slope

End Bay LengthEnd Bay Length

Interior Bay LengthInterior Bay Length

Design LoadsDesign Loads

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Basic Building Parameter of PEBBasic Building Parameter of PEB

Building WidthBuilding Width

is defined as the distance from outside of eave strut is defined as the distance from outside of eave strut of one sidewall to outside of eave strut of the of one sidewall to outside of eave strut of the opposite sidewall opposite sidewall

Building LengthBuilding Length

the distance between the outside flanges of end-the distance between the outside flanges of end-wall columns in opposite end-walls is the building wall columns in opposite end-walls is the building length. It is a combination of several bay lengthslength. It is a combination of several bay lengths

Building HeightBuilding Height

is the eave height which usually is the distance is the eave height which usually is the distance from the bottom of the main frame column base from the bottom of the main frame column base plate to the top outer point of the eave strut plate to the top outer point of the eave strut

1010

Roof SlopeRoof Slope (x/10): (x/10):This is the angle of the roof with respect to the This is the angle of the roof with respect to the horizontal. The most common roof slopes are 0.5/10 horizontal. The most common roof slopes are 0.5/10 and 1/10. Any practical roof slope is possible.and 1/10. Any practical roof slope is possible.

End bay lengthEnd bay length::The distance from outside of the outer flange of end-The distance from outside of the outer flange of end-wall columns to center line of the first interior frame wall columns to center line of the first interior frame column.column.

Interior bay lengthInterior bay length::The distance between the center lines of two adjacent The distance between the center lines of two adjacent interior main frame columns. The most common bay interior main frame columns. The most common bay lengths are 6 m, 7.5 m and 9 m.lengths are 6 m, 7.5 m and 9 m.

Design LoadsDesign Loads::Usually:Usually:Roof Live Load: 0.57 kN/m2Roof Live Load: 0.57 kN/m2Design Wind Speed: 110 km/hDesign Wind Speed: 110 km/h

Basic Building Parameter of PEBBasic Building Parameter of PEB

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Advantages of PEBAdvantages of PEB Structure weightStructure weight

Lighter 30%, primary framing members are Lighter 30%, primary framing members are tapered built up sections with larger depths in the tapered built up sections with larger depths in the areas of highest stressareas of highest stress

DesignDesignQuick and efficient since mainly formed of Quick and efficient since mainly formed of standard sections and connectionsstandard sections and connectionsUsing software analysis for calculation and Using software analysis for calculation and drawingsdrawings

FoundationsFoundationsSimply design, easy to construct and lightweightSimply design, easy to construct and lightweight

Erection simplicityErection simplicityfaster in erection, supported by vendor’s erection faster in erection, supported by vendor’s erection supervisorsupervisor

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Advantages of PEB (Continued)Advantages of PEB (Continued)

Seismic resistanceSeismic resistanceThe low weight flexible frames offer higher The low weight flexible frames offer higher resistances to seismic forcesresistances to seismic forces

Overall pricesOverall pricesPrice per square meter may be as much as 30% Price per square meter may be as much as 30% lower than conventional steellower than conventional steel

Sourcing and coordinationSourcing and coordinationSupplied complete with cladding and all Supplied complete with cladding and all accessoriesaccessories

Cost of changeCost of changeLittle or no material is wasted even if a change of Little or no material is wasted even if a change of order is made after fabrication starts order is made after fabrication starts

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Applications of Pre-Engineered BuildingsApplications of Pre-Engineered Buildings

IndustrialIndustrial FactoriesFactories WorkshopsWorkshops WarehousesWarehouses Cold storesCold stores Car parking shedsCar parking sheds Slaughter housesSlaughter houses Bulk product storaBulk product stora

gege

Commercial Commercial ShowroomsShowrooms Distribution centerDistribution center

ss

SupermarketsSupermarkets RestaurantsRestaurants OfficesOffices Service stationsService stations Shopping centersShopping centers

Institutional Institutional SchoolsSchools Exhibition hallsExhibition halls HospitalsHospitals TheatersTheaters AuditoriumsAuditoriums Sports hallsSports halls

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Applications of Pre-Engineered BuildingsApplications of Pre-Engineered Buildings

Heavy Industrial Heavy Industrial Cement PlantsCement Plants Steel rolling millsSteel rolling mills Sugar millsSugar mills Ceramic factoriesCeramic factories

Aviation & MilitaryAviation & Military Aircraft hangersAircraft hangers Administration BuildAdministration Build

ingsings

Residential barracksResidential barracks Support facilities Support facilities

Recreational Recreational Gymnasiums Gymnasiums Swimming Swimming

pool pool enclosures enclosures

Indoor tennis Indoor tennis courtscourts

Agricultural Agricultural Poultry-Dairy Farms Poultry-Dairy Farms Greenhouses Greenhouses Grain storage Grain storage Animal confinement Animal confinement Pump stations Pump stations

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Use of PEB in Fire Station and Use of PEB in Fire Station and Emergency Clinic Building Project; Emergency Clinic Building Project; the Implementation the Implementation of of VE ConceptVE Concept

Project OverviewProject Overview

Project objective is to Project objective is to build a new facility for Fire Station for build a new facility for Fire Station for reliable operation to back up the existing operation reliable operation to back up the existing operation especially to response emergency cases. The new building especially to response emergency cases. The new building will accommodate office staffs, training room, parking of will accommodate office staffs, training room, parking of fire truck equipment, gymnasium and include clinic facilitiesfire truck equipment, gymnasium and include clinic facilities

Project Owner: General Manager EHS PT IncoProject Owner: General Manager EHS PT Inco Scope of works: comprised geotechnical/civil and structural, Scope of works: comprised geotechnical/civil and structural,

mechanical, electrical and instrumentationmechanical, electrical and instrumentation Project team were taken from Central Engineering PT Inco Project team were taken from Central Engineering PT Inco

consist of project manager, project engineer, design consist of project manager, project engineer, design engineer (civil, mechanical, electrical and instrument)engineer (civil, mechanical, electrical and instrument)

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Building LayoutBuilding Layout

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Key Aspects to Decide using PEB System Key Aspects to Decide using PEB System onon Design PhaseDesign Phase

Budget constraintBudget constraintLess budget allowed by business case that was Less budget allowed by business case that was presented by project sponsorpresented by project sponsor

Time consumptionTime consumptionMore time required to develop design calculation, More time required to develop design calculation, detail drawing and so on by in-house engineering. By detail drawing and so on by in-house engineering. By PEB concept, project engineer only sent the building PEB concept, project engineer only sent the building parameter to vendor (drawing layout and parameter to vendor (drawing layout and specifications)specifications)

Bidding list had also shown the price differences Bidding list had also shown the price differences between conventional steel and pre-engineered between conventional steel and pre-engineered building. It was proven from in-house engineering building. It was proven from in-house engineering designs using conventional steel, the price of PEB is designs using conventional steel, the price of PEB is 30% cheaper 30% cheaper

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Comparison between PEB and Conventional Steel Comparison between PEB and Conventional Steel PricePrice

1919

Cross Section of Structures resulted from In-house Cross Section of Structures resulted from In-house

Engineering Design CalculationsEngineering Design Calculations

2020

Vendor Drawing Submission by PEB VendorVendor Drawing Submission by PEB Vendor

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Product of Pre-Engineered Building on this Product of Pre-Engineered Building on this ProjectProject

Design ProductDesign Product• Design information such as applicable design Design information such as applicable design

codes, material specifications, design codes, material specifications, design assumptions and load combinations, design assumptions and load combinations, design summary, plan and elevations, frame cross summary, plan and elevations, frame cross section, roof extension details, portal frame section, roof extension details, portal frame details, column reaction, drainage design, and details, column reaction, drainage design, and bracing designbracing design

• Computer design print outsComputer design print outs• Design reference tables and computer Design reference tables and computer

explanationsexplanations• Construction drawingsConstruction drawings

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Product of Pre-Engineered Building on this Product of Pre-Engineered Building on this ProjectProject

Construction ProductConstruction Product

The construction product as a process and The construction product as a process and result of delivery and construction stagesresult of delivery and construction stages as as follows:follows:

• PEB PEB ssteel materialsteel materials• Shipment to siteShipment to site• Supervision during erectionSupervision during erection• Punch list and commissioningPunch list and commissioning• Owner’s mOwner’s maintenance manual for PEB aintenance manual for PEB

system provided by system provided by vvendorendor

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Lessons Learned and Conclusion taken Lessons Learned and Conclusion taken from Projectfrom Project

PProfessional engineerrofessional engineer must be must be open minded to new ideas, open minded to new ideas, new innovations and technologies. There are always new innovations and technologies. There are always opportunities to try something new on the project that is opportunities to try something new on the project that is possible to give more benefits to the successful of the possible to give more benefits to the successful of the project. PEB system is actually an old technologyproject. PEB system is actually an old technology in low in low rise buildings,rise buildings, unfortunately, currently some of in house unfortunately, currently some of in house civil engineers are only focusing on conventional steel civil engineers are only focusing on conventional steel experiences.experiences.

Value engineering concept is very applicable on design Value engineering concept is very applicable on design phases where the engineers could save more money phases where the engineers could save more money without reducing the utility or function of final products.without reducing the utility or function of final products.

The use of pre-engineered building could benefit both The use of pre-engineered building could benefit both engineers (project engineer) and constructors. Engineer engineers (project engineer) and constructors. Engineer was only doing FEED stage to produce the layout and was only doing FEED stage to produce the layout and specification and then the EPCI work will be performed by specification and then the EPCI work will be performed by the constructor + PEB vendor easily. the constructor + PEB vendor easily.

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ReferencesReferences

Fisk, R., Edward (2003). Construction Project Fisk, R., Edward (2003). Construction Project Administration. Prentice Hall Upper Saddle River, Administration. Prentice Hall Upper Saddle River, New Jersey, Columbus, Ohio: 2003New Jersey, Columbus, Ohio: 2003

Zamil Steel Website. Zamil Steel Website. http://zamilsteel.com/peb/en/default.asp?iID=LJJME, http://zamilsteel.com/peb/en/default.asp?iID=LJJME, 20092009

Wikipedia Website. http://en.wikipedia.org/wiki/Pre-Wikipedia Website. http://en.wikipedia.org/wiki/Pre-engineered_building, 2009engineered_building, 2009

Engineering Procedures Manual. PT International Engineering Procedures Manual. PT International Nickel Indonesia, 2006Nickel Indonesia, 2006