UNIVERSITI TEKNOLOGI MARA CAWANGAN PERAK

KAMPUS SERI ISKANDAR

FACULTY OF ARCHITECTURE, PLANNING AND SURVEYING
DEPARTMENT OF BUILDING

MANUFACTURING TECHNOLOGY (BCT 554)

TOPIC: IMPLEMENTATION OF MANUFACTURING IBS COMPONENT
(LIGHT GAUGE STEEL FRAME)
GROUP MEMBER:
NAME STUDENT ID
AIDIL HAKEEM BIN AZIZAN 2020995227
AHMAD SAFARUDDIN BIN MOHD NASIR 2020986181
NAJIHA BINTI AZMI 2020963175
NUR AINIE IZATIE BINTI NONAZAHAR 2020963403
SHARIFAH NUR ATIQAH BINTI SYED MUZZAFAR 2020963365
SHAH
 INTRODUCTION

Light steel frame have the advantage of lightness, high load-bearing capacity and a
wide range of possible uses. In some countries, quite a large proportion of private houses and
multi-storey residential buildings are also being built at low cost with light steel section. New
products in thin steel sheets, combined with improved plating and insulating materials, make
steel an interesting option with an increasing number of application in modern construction.
(European lightweight steel frame)
Instead of a more traditional approach, which consists of the use of concrete and
brick, the structure of a house will consist of resistant walls composed of several metal
profiles in galvanized steel of small thickness and covered by several types of sheathings. It
should be noted at the outset that the key word in this concept is Light, since it is its main
characteristic and from here advent all its advantages. Because of this lightness, each element
is easy to transport, handle, and assemble, reducing the time of construction, and the
equipment needed. Furthermore, since steel is mostly priced by the weight, light elements
will be cheaper. (302950)
Light Gauge Framed Steel Structure (LGFSS) is based on factory made galvanized
light gauge steel components produced by the cold forming method assembled as panels at
site forming structural steel framework of a building and varying wall and floor construction
as detailed in this Certificate. The panels are assembled on site with screws and bolts to form
the internal and separating walls and inner leaf of the external walls of a building and floors
& ceiling. The building is completed by the installation of an external layer of insulation
material and outer leaf of CP Board or dry mix shot Crete. (28pacslgsff)
The light gauge steel members are defined as structural member cold formed to
shapes in cold-rolling machines or press brakes or bending brake operations from carbon or
low-alloy steel sheets or strips or flats. The thickness of such members usually range from
0.378mm to about 6.35mm, even though steel plates as thick as 25.4mm may be cold formed
into structural shapes. These thin steel sections are called cold formed as their manufacturing
process of forming steel sections remains in a cold state. These are also known as cold rolled
steel sections against hot rolled sections.
THE WORK PROCESS OF LIGHT GAUGE STEEL FRAME

Receiving raw material,

Inspection and Store

Loading the coils in the

De-coiler

Levelling the steel strip

Press and Punching

Roll forming

Cutting

Stacking solution
 Production stock

Assembly and dispatch to

construction site
 PROCEDURE DIAGRAM
1. Receiving raw material,
Inspection and Store

Cold-formed steel structural

members shall match with the
specified size, type, mechanical
properties and spacing. The framing
members shall not be damaged.
Damaged members shall be replaced
or repaired in accordance with
approved design.
2. Loading the coils in the De-coiler

The de-coiling is the operation

which takes place on de-coiler
machine, the de-coiling operation
consists of unwinding the coil which
is to be turn around the jaw of de-
coiler machine. After loading the
metal coils, user can easily adjust
tightening of coil by external arm
with the tightening system. Coil cars
move forward-backward, up and
down with hydraulic system.

3. Levelling the steel strip

As the coil unrolled from the rolled

coil which is progress through
levelling machine. Levelling is
action done on levelling machine.
Levelling is the highly professional
action which carry out to avoid
problems that occurs in coil
machining process such as cutting,
shearing, etc. The levelling is one of
the simple technique use to receive
flat sheets which are free from
internal stresses that results in
saving of end product from scrap.
4. Press and Punching

Once the material is levelled, it is

then transported to the press
machine for metal forming process.
A punching machine installed in the
machine base of a roller shape
forming machine in a metal working
system and controlled to punch
holes on a metal sheet material
being delivered through the roller
shape forming machine during
operation of the roller shape forming
machine.
5. Roll forming

The shape is coaxed from the

starting flat strip into the final shape
by a series of roller dies that are
ideally already on-hand in their
inventory. Each stack of rollers adds
a small additional forming step to
the strip, so that by the end of the
line, the width of the strip has been
formed into the required cross-
sectional shape
6. Cutting

Shapes can be cut to precise length

after they are done with the roll
forming part of the system with a
Cut-Off. This style of cut-off allows
for cutting, while the system is still
moving the sheet metal through the
roller dies, increasing throughput.
7. Stacking solution

Once they are cut, the part is then

discharged onto a run-out table, so
the operator can place it in
protective crating for storage or
shipment.
8. Production stock

Assign separate areas for storing

structural steel of different classes,
sizes and lengths. Store it above
ground level by at least 150 mm
upon platforms, skids or any other
suitable supports to avoid distortion
of sections.

9. Assembly and dispatch to

construction site

The frame is fixed together using

specialist screw gun the table is
positioned in a way that allow
assemblers to move freely around
the assembly area. The frame master
operator will keep a record of every
element that is manufactured to
ensure that it is fully complete
before they are dispatched to the
site.
2.0 MATERIAL HANDLING AND MANAGEMENT

During the storage and handling of steel and other metal stocks, many incidents, some
resulting in death and serious injury, continue to occur. In addition to the human tragedy
involved, they produce immense social and economic costs. It is in the interest of everyone
that they are reduced. Investigations into incidents also reveal that these injuries should have
been prevented. This is the reason why material handling and management are important such
as storage system, lifting equipment that suits with the weight of the product, and lifting
accessories that suitable.

2.1 Storage and storage system

2.1.1 Rollstop system
RollStop system consists of rails constructed from reinforced plastic. Rails and
blocks are thus indestructible and very elastic. The system of principle is
versatile, can be used with coils of any diameter, does not affect coils and does
not absorb any liquid. Plastic blocks, depending on the diameter of the coils,
may be positioned at various distances from each other. The mechanism flexes
slightly (dampens) when subject to loading and returns to its initial state as
soon as the coils are removed. This makes it possible to prevent coil damage.
Figure 2.1 shows the rollstop system are applied.

Figure 2.1 Rollstop system

2.1.2 Cradles (chairs)
Cradles (chairs) are individual coil supports and are usually made of from
wood or steel. To help the base level of a multi-level stack of coils, they are
often (rarely) put in rows. The cradle is banded to the coil's base
occasionally. For the purposes of lifting/handling, sufficient handling,
equipment should be connected to the coil itself. Forklift trucks may be
used to lift coil-carrying cradles if the cradles themselves are designed to
be handled in this way. Figure 2.2 shows the wooden cradles.

Figure 2.2 Wooden cradles

2.1.5 Cantilever rack
Cantilever rack are known as a storage system that designed to store long,
bulky materials of visually any length. As light steel frame are really need
proper handling and management, this cantilever rack are used to ensure
that there are no defect on steel frame. Cantilever racks are unlike any other
rack systems, as it offer no vertical obstructions in the storage area. Figure
2.3 shows the cantilever rack used.

Figure 2.3 Cantilever rack

2.2 Lifting equipment
2.2.1 Overhead travelling cranes
Two wide types of overhead travelling cranes are available, twin-hoist
cranes and single-hoist cranes. They may be equipped with infra-red or
radio-controlled operating devices in order to allow operators to remain
further away from the load than when using a regular pendant. For long
and/or versatile items, twin hoist cranes are preferable. In particular, if there
is access to both ends of the stock, they will significantly reduce the need
for slingers to reach storage racks or climb and walk on stored objects.
Figure 2.4 shows the overhead cranes and figure 2.5 shows the overhead
cranes with c-hooks used for lifting the galvanised coil.

Figure 2.4 overhead crane

Figure 2.5 Overhead crane with c-hooks

2.2.2 Vehicle-mounted cranes
These are used to load or unload stock from and onto vehicles for distribution.
Figure 2.6 shows the vehicle-mounted cranes been used.

Figure 2.6 Vehicle-mounted crane

2.2.3 Jib-cranes
Swing jib cranes are usually suspended and used for different operations.
Including stock loading on vehicles or machinery. Figure 2.7 shows the jib-
cranes are used at the factory.

Figure 2.7 Jib cranes

2.3 Lifting accessories for light steel product handling
2.3.1 Fish plates and splitters
Fish plates and splitters are used to lift one end of a package or a secure
product stack, facilitating the splitting and separating of larger bundles for
lifting purposes. To allow a chain sling to be attached, this also requires
placing battens between the items being separated. As they are not built for
non-vertical lifting and can easily slip, the hoist must always be placed directly
above the fish plate or splitter. Figure 2.8 shows the fish plates are used to lift
the product.

Figure 2.8 Fish plates and splitters

2.4 Lifting accessories for coil-handling accessories
2.4.1 C-hooks
A 'turning C-hook' which allows the vertical plane to be raised to coils that are
lying flat. When using turning hooks, there is a minimum and a maximum coil
width to be considered. To transform a coil from vertical to horizontal with a
turning c-hook, a 'turning shoe' is required. Figure 2.9 shows the C-hooks
accessories are used.

Figure 2.9 C-hooks

2.4.2 Telescopic coil lifters
These are advanced coil-handling machines that allow lifting operations to be
managed from a safe distance. They are double C-hooks that are driven and
used to lift larger coils. To allow coils to be rotated during the lift, universal
pivots are normally fitted. Figure 2.10 shows the telescopic coil lifters are
used.

Figure 2.10 Telescopic coil lifters

2.5 Industrial trucks
2.5.1 Forklift truck
Forklift trucks are typically used for stock raising and moving. The
counterbalanced truck is the most widely used in a number of sizes and styles.
Smaller electric trucks are better suited for indoor use and larger diesel trucks
are best suited for outdoor use. Figure 2.11 shows the forklift use to carry the
product out to the factory.

Figure 2.11 Forklift

PRODUCTION PLANNING OF LIGHT GAUGE STEEL
Have 4 step:
 Step 1 : vertex BD design software
Construction design through Vertex BD design software, design data NC output to
production software.

 Step 2 : HBS LGS Production System.

Input design data from Vertec BD NC output. Self-develop HBS LGS production
system control the production equipment and refine the frame structure.

 Step 3 : HBS machine

The PLC panel is able to make clear to each component production current process.
It can timely reproduce any failed products resulted from any reasons in the
production process.

 Step 4 : assembly
Different components have independent inkjet coding. Assembly as per the drawing
from Vertex BD software.

Have 2 feature:
 Feature 1 : Material saving

With the output code of Vertex software, there is always an inevitable material waste
of 45-50mm when it comes to one part with chamfer cut or with flat cut, such wastage
can amazingly reach 1.7-2.1%. Based on above calculation, a yearly production of
5000 Ton approximate will generate 100 tons wastes. However, in view of this
situation, HBS LGS production system has made a serials optimization, which
minimizes the wastage to a minimum.

Traditional wastes material between each pieces

 HBS Equipment controlled the waste to a minimum

 Feature 2 : No jammed on machine.

In many cases, when it comes to large door and windows there is a special design on
the header, Crip stud or Jack stud. To ensure the structure intensity, the designer
would normally design the column parts into groups. Such structure are rather easy
to jam the machine. It might take at least 1 hours to debug machine with a skill full
operator. The roller space has to be readjusted after the debug. Otherwise it may
bring several damages like Shafter breaking, roller crushing and so on. Sheet are
wasted again during the machine readjusting.

HBS has invested capital & resource in improving LGS equipment especially on the
roll forming station & shearing station to make sure machine won’t jammed while
producing special columns.
 MACHANISED DEVICE

Specification:

Operation process:

De-coiler Leveling Device Punching Device

Out-let table Cutting Device Roll Forming System

Machine Components
 De-coiler Type: Auto Hydraulic de-coiler
Weight capacity: 3.0T
 Punching
All punching dies are made from Cr12Mov.
Holes parameter is able to set by computer; Hole Type can be customized.

 Rolling Forming System

Main motor type: servo motor
Speed of forming: 48m/min
Roller: 12 groups of rollers.
Shaft & Frame: Shafts of rollers are tooled by grinding machine for two times to
ensure the precision of final product.
The frame is designed as strong as required to bear the whole rollers and
shafts. Material of main shaft : 40Cr.
Machine frame Material of frame: A3

 Hydraulic Cutting
Cutting material: Cr12MoV

 Online printer
Online inkjet printing system. Marks and Item Number are available to be
printed on the flange side for easy assembling pieces to pieces.

 Out-let Table
4 meter Product support frame
C stud to the stack platform

 Safety Guard
Safety Guard covers the whole machine to ensure worker’s safe.
 Computer system.

 Control panel
Control the quantity & punching length & cutting length automatically
The Machine will be stopped while it is punching and cutting
Automatic Length measures and quantity counting (precision +- 1mm)
Design Software Part – Vertex BD Pro
 TECHNICAL PARAMETERS

Ⅰ、Adjusted sizes:
Width: 75-220mm
Height: 32-51mm
(Lips: 8-15mm)
Coil thickness: 0.8-1.6mm

1.C profile

2.U profile
1）material : galvanized coil, aluminum-zinc coilSGC570 gradeyield strength :550Mpa.
2）Tensile Strength: 355Mpa, 386Mpa,480Mpa

Machine Components
HydraulicDe-coiler ————————————————————- 1 set
Leveling Device —————————————————————— 1 set
Roll Forming System————————————————————- 1set
Online Printer——————————————————————— 1 set
Punching & Cutting Device ————————————————— 1 set
PLC Control System————————————————————– 1 set
Hydraulic Station—————————————————————– 1 set
Run out table———————————————————————- 1 set

Flow Chart

The flow chart is showing below.

Auto De-coiler→Leveling Device→Roll Forming System→Punching & Cutting Device →Run
out tabl
Machine Picture

Technology Parameters
The weight of theMachine:About 5.0T
The total dimension with un-coiler, run out table is:
(length)13m x (width)1.2m x (height)1.6m.

1)De–coiler
De-coiler Type:Hydraulicauto de-coiler
Weight capacity: Max 3.0T
Guiding: Guiding device is used to guide and fasten the raw material raw material into roll
forming station steadily.

3) Rolling Forming System

MaSpeed of forming: 35m/min
Roller stands : 15rolling stands.

4) Shaft & Frame:

Shafts of rollers are tooled by grinding machine for two times to ensure the precisionof final
product.
Bearing: NTN brand from Japan.

6)Machine Frame
The frame of machine are designed as square tube shape and thickness of frame is 30mm
in order to make sure the machine is capable to bear all accessories of this machine
7) Flare control rollers
Flare device is made of two group rollers with manual adjusting device.
8)Changing sizes: Full-automatic (change sizes by PC control system)
Machine is able to change purlin size within 1 minutes.
9)Hydraulic Punching
All punching dies are made from Cr12. Driven by hydraulic station.Holes locations are able
to set by PC panel.
10)Hydraulic cutting
After punching, the cutter will shear the raw material automatically, driving raw material out
of roll forming system. Shearing type: Hydraulic shearing with guillotine cutting.Cutting
material: Cr12
11) Run out table
4 meter material receiving table, with a C stud & Track stacking platform.

Safety Guard:Safety Guard covers the whole machine to ensure worker’s

PC control system LG-R300.
The control system MF 20 is able to program production CNCby inputingDahe’sTXT or CSV
format and connect with machine directly. It can control machine auto-runningandrunning
status dynamically, including punching, cutting and size changing.

15) PLC Control System & Components

Control the quantity &punching length& cutting length automatically
The Machine will be stopped while it is punching and cutting
Automatic Length measures and quantity counting (precision +-0.5mm)

16) Profile image and application

 CONCLUSION

Industrialized Building System (IBS) is a term coined by Malaysia’s industry and

government to describe the adoption of industrialization of construction and the use of
part prefabrication in construction. As building elements, IBS construction consists of
precast part systems, manufactured steel structures, revolutionary mould systems,
modular block systems, and prefabricated timber structures. Construction stakeholders
have begun to adopt IBS to achieve improved quality and efficiency of construction,
reduce workplace safety and health hazards, mitigate skilled worker problems and
reliance on manual foreign labour, and achieve the ultimate goal of reducing higher
construction costs.
The implementation of IBS allows the industry to undergo major structural
transformation. IBS alters the way people work in construction industry, both in terms of
process and in terms of the product. It is only through a detailed understanding of the
concepts underpinning production that the real benefits of IBS can be understood, while
also appreciating the limitations and pitfalls of a fragmented construction industry. It
could be flawed to conclude that market intelligence determines that the existing
approaches are sufficient. Enough industry players are calling for a major shift toward
IBS, indicating that consumer sentiments are rapidly shifting. Indeed, IBS provides the
industry with endless opportunities and one can no longer feel threatened. It has become
time to build an inclusive, collaborative business that can support the industry and the
nation as whole from one another.
Furthermore, the entry of specialist prefabrication sub-contractors could further
sustain competition in the public construction industry. To compete for IBS works
outsourced by contractors who do not have their own in-house plants to produce the
components, a cluster of specialist contractors, similar to those in the construction
services sector in particular, will enter the market. Instead, in this new field of play that
has been developed to spur our growth, one needs to begin strategizing and capitalising
on market positioning. In addition, it is important for Malaysia contractors to venture
overseas to tap into the global market.