design phase constructability concepts in siti hafizan binti...
TRANSCRIPT
DESIGN PHASE CONSTRUCTABILITY CONCEPTS IN
HIGHWAY PROJECTS
SITI HAFIZAN BINTI HASSAN
A project report submitted in partial fulfilment of the
requirements for the award of the degree of
Master of Science (Construction Management)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
NOVEMBER 2005
iii
To my beloved mother and father, my families, my lecturers, my friends and
my special friend…..Thanks for the everlasting love and supports…..
iv
ACKNOWLEDGEMENTS
First and foremost, grateful thanks to Allah S.W.T for guiding and helping me in
this dissertation. Giving me chances in a way to complete it.
I would like to extend my deepest appreciation and thanks to my supervisor,
Ir. Dr. Rosli Mohamad Zin for his continuous guidance and encouragement in the effort
to complete this thesis.
I would also like to thank to all the engineers and architects who participated in
the questionnaires survey and field interviews and also to those who were involved
directly or indirectly in the completion of this project.
Last but not least is my appreciation and gratitude to my mum, Puan Wan
Fatimah, my dad, Encik Hassan, my brother, Encik Abdul Aziz, my families, my
friends, Idris, Nik Zilazmi, Fareh, Roslina, Lenny, Aiza and Hasnizar for their
understanding, support and encouragement.
v
ABSTRACT
Nowadays, highway construction projects suffer from lack of constructability, which
causes many problems; traffic, substantial number of changes, poor planning, disputes,
cost overruns, poor safety practices and time delays. Some researchers have realized the
seriousness of this shortfall and have suggested solutions to resolve it. Previous studies
indicate that, overall constructability is not being implemented to its full potential in
highway sector. So, this study tries to explore constructability implementation in the
local construction industry particularly the highway sector. The aim of the study is to
establish guideline that can be used by engineers in order to improve constructability of
highway project design. The findings of the study shows there were eighteen design
phase constructability concepts that are ‘very important’ and ‘important’ in highway
sector. For the level of application, it was found that most of the concepts are in
‘medium application’. It can be concluded that the engineers have the constructability
knowledge but lack of understanding of the concepts. Based on the survey exercise, a
guideline has been developed consisting of two parts which are ‘very important’ and
‘important’. It is expected that by having this guideline, engineers will be able to apply
this concepts effectively in highway project design in Malaysia.
vi
ABSTRAK
Kesan daripada kurangnya aplikasi kebolehbinaan dalam pembinaan jalanraya pada
masa kini telah menyebabkan berlakunya banyak masalah dalam pembinaan seperti
lalulintas, perubahan rekabentuk, perancangan yang lemah, pertikaian, kos projek yang
melebihi nilai projek sebenar, sistem keselamatan yang lemah, serta kelewatan masa
penyiapan projek itu sendiri. Para penyelidik telah mengenalpasti betapa seriusnya
masalah ini dan telah mencadangkan beberapa penyelesaian dalam menyelesaikannya.
Kajian terdahulu menunjukkan bahawa keseluruhan kebolehbinaan ini tidak
dilaksanakan secara sepenuhnya di dalam projek jalanraya. Maka, kajian ini cuba
meninjau perlaksanaan kebolehbinaan ini di dalam projek pembinaan jalanraya
setempat. Matlamat kajian ini adalah untuk menghasilkan satu garis panduan agar boleh
digunakan oleh para jurutera dalam usaha untuk mempertingkatkan lagi penggunaan
kebolehbinaan dalam fasa rekabentuk di dalam projek jalanraya. Hasil daripada kajian
ini menunjukkan bahawa lapan belas konsep kebolehbinaan yang dikaji adalah ‘sangat
penting’ dan ‘penting’ dalam projek jalanraya. Dari segi tahap penggunaan konsep ini
pula, didapati bahawa semua lapan belas konsep yang dikaji di bawah kedudukan
‘penggunaan pertengahan’. Dapat disimpulkan bahawa jurutera di Malaysia mempunyai
pengetahuan mengenai kebolehbinaan ini, tetapi kurangnya pemahaman dari segi
konsep-konsepnya. Berdasarkan pemerhatian kajian yang dijalankan, garis panduan
telah dibentuk di mana ia mengandungi dua bahagian iaitu ‘sangat penting’ dan
‘penting’. Adalah dijangkakan bahawa dengan adanya garis panduan ini, jurutera boleh
mengaplikasikan konsep-konsep ini secara berkesan di dalam rekabentuk projek-projek
jalanraya di Malaysia.
vii
TABLE OF CONTENT
CHAPTER TITLE PAGE
THESIS TITLE i
DECLARATION SHEET ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK vi
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xiv
LIST OF APPENDIX xvi
1 INTRODUCTION 1
1.1 Introduction 1
1.2 Problem Statement 3
1.3 Aim and Objectives of the Study 4
1.4 Scope of Research 4
1.5 Research Methodology 4
viii
2 LITERATURE REVIEW 6
2.1 Constructability Definitions 6
2.2 General Overview Constructability in 7
Highway Project
2.2.1 Government Agency Observations 8
2.2.2 Design Firm Observations 11
2.2.3 Construction Firm Observations 14
2.3 Constructability in the Highway 14
Construction Project Process
2.3.1 Feasibility Design Stages 16
2.3.2 Design Stages 17
2.3.3 Construction 18
2.3.4 Operation 18
2.4 Maximum Benefit of Constructability 19
2.5 Constructability Concepts in Highway Projects 22
2.6 Design Phase Constructability Concepts 32
2.6.1 Carry Out Thorough Investigation of the Site 34
2.6.2 Design for Minimum Time Below Ground 36
2.6.3 Design for Simple Assembly 39
2.6.4 Encourage Standardisation/Repetition 40
2.6.5 Design for Preassembly or Modularisation 40
2.6.6 Analyse Accessibility of the Jobsite 41
2.6.7 Employ Any Visualisation Tools 42
to Avoid Physical Interference
2.6.8 Investigate Any Unsuspected Unrealistic 42
or Incompatible Tolerances
2.6.9 Investigate the Practical Sequence of 43
Construction
2.6.10 Plan to Avoid Damage to Work by 43
Subsequent Operations
ix
2.6.11 Consider Storage Requirement at 43
the Jobsite
2.6.12 Investigate the Impacts of Design on 44
Safety during Construction
2.6.13 Design to Avoid Return Visit by Trade 45
2.6.14 Design for the Skills and Resources 45
Available
2.6.15 Consider Suitability of Designed Materials 46
2.6.16 Provide Detail and Clear Information 45
2.6.17 Design for Early Enclosure 46
2.6.18 Consider Weather Effect in Selecting
Materials or Construction Methods 47
2.7 Summary 48
3 RESEARCH METHODOLOGY
3.1 Introduction 50
3.2 Research Process 50
3.3 Determining the Research Objectives 51
3.4 Steps in Methodology 52
3.4.1 Conceptualization 52
3.4.2 Literature Review 53
3.4.3 Questionnaire 53
3.4.4 Analysis 56
3.5 Development of Guidelines 57
4 DATA ANALYSIS AND DISCUSSION
4.1 Introduction 58
4.2 Respondent’s Background 59
4.2.1 Type of Organization 59
4.2.2 Level of Education 60
x
4.2.3 Field of Specialization 61
4.2.4 Position in Organization 62
4.2.5 Numbers of Years Practiced in Designing 63
4.2.6 Numbers of Years Practiced in Working 64
4.3 Level of Importance 66
4.3.1 Frequency Analysis 66
4.3.2 Average Index Analysis 77
4.4 Level of Application 81
4.3.3 Frequency Analysis 81
4.3.4 Average Index Analysis 91
4.5 The Development of Design Phase 95
Constructability Improvement Concepts
4.6 Discussion 99
5 CONCLUSION AND RECOMMENDATIONS
5.1 Conclusion 100
5.1.1 Objective 1 100
5.1.2 Objective 2 104
5.1.3 Objective 3 105
5.2 Recommendations 105
REFERENCES 107
APPENDIX 110
xi
LIST OF TABLES
TABLE NO. TITLE PAGE
4.1 Type of Organization 59
4.2 Level of Education 61
4.3 Field Of Specialization 62
4.4 Position in Organization 63
4.5 Number of Years Practiced in Designing in 64
Highway Projects
4.6 Number of Years Practiced in Working in 65
Highway Projects
4.7 Carry out Thorough Investigation of the Site 66
4.8 Provide Detail and Clear Design Information 67
4.9 Analyze Accessibility of the Jobsite 67
4.10 Investigate the Impacts of Design on Safety 68
during Construction
4.11 Consider Suitability of Designed Materials 69
4.12 Investigate the Practical Sequence of Construction 69
4.13 Consider Adverse Weather Effect in Selecting Materials 70
or Construction Methods
4.14 Plan to Avoid Damage to Work by Subsequent 71
Operations
4.15 Investigate Any Unsuspected Unrealistic or 71
xii
Incompatible Tolerances
4.16 Designs for the Skills and Resources Available 72
4.17 Consider Storage Requirement at the Jobsite 72
4.18 Design for Minimum Time below Ground 73
4.19 Design for Early Enclosure 73
4.20 Encourage Standardization/Repetition 74
4.21 Employ Any Visualization Tools to Avoid 74
Physical Interference
4.22 Design for Simply Assembly 75
4.23 Design to Avoid Return Visit by Trade 76
4.24 Design for Preassembly and/or Modularization 76
4.25 Average Index Value for Degree of Importance of 79
Constructability Concepts during the Design Phase
4.26 Carry Out Thorough Investigation of the Site 81
4.27 Employ Any Visualization Tools to Avoid 82
Physical Interference
4.28 Encourage Standardization/Repetition 82
4.29 Consider Storage Requirement at the Jobsite 83
4.30 Design for Minimum Time below Ground 83
4.31 Investigate the Practical Sequence of Construction 84
4.32 Design for Simply Assembly 84
4.33 Design for the Skills and Resources Available 85
4.34 Investigate the Impacts of Design on Safety during 86
Construction
4.35 Analyze Accessibility of the Jobsite 86
4.36 Design For Preassembly and/or Modularization 87
4.37 Investigate Any Unsuspected Unrealistic or 87
Incompatible Tolerances
4.38 Design to Avoid Return Visit by Trade 88
4.39 Design for Early Enclosure 88
4.40 Provide Detail and Clear Design Information 89
xiii
4.41 Plan to Avoid Damage to Work by Subsequent 89
Operations
4.42 Consider Suitability of Designed Materials 90
4.43 Consider Adverse Weather Effect in Selecting Materials 90
or Construction Methods
4.44 Average Index Value for Degree of Application of 93
Constructability Concepts during the Design Phase
xiv
LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Research Methodology Chart 5
2.1 The Highway Construction Project Process 16
2.2 Project Life Cycle and Designers Level of Influence 20
2.3 Ability to Influence Final Cost Over Project Life 21
2.4 Process of launching girder for elevated structure 35
2.5 Problems faced during launching of some girders 35
2.6 Details of elevated highway 37
2.7 Problem of compaction and result after 38
project start-up
3.1 Steps in Methodology 52
3.2 Questionnaire Flow Chart 55
4.1 Percentage of type of organization 60
4.2 Percentage of level of education 61
4.3 Percentage of field of specialization 62
4.4 Percentage of Position in Organization 63
4.5 Percentage of Number of Years Practiced in 64
Designing In Highway Projects
4.6 Number of Years Practiced in Working in 65
Highway Projects
4.7 Degree of Importance of Constructability Concepts 80
xv
4.8 Degree of Application of Constructability Concepts 94
4.9 Design Phase Constructability Improvement Concepts 96
For Malaysian Highway Projects
xvi
LIST OF APPENDIX
APPENDIX TITLE PAGE
A Questionnaire Form 110
CHAPTER 1
INTRODUCTION
1.1 Introduction
Government and private agencies that carried out highway construction
project are facing the reality that the public will no longer tolerate construction
projects that are insensitive to road users and adjacent communities. According to
Russell et al. (1993), highway construction projects are characterized by traffic
problems, changes of design, poor planning, disputes, cost overruns, poor safety
practices and time delays. Constructability is seen as one of the best solutions to
these problems where it has demonstrated the potential to minimize the number and
magnitude of changes, disputes, cost overruns, and delays during construction.
Constructability has been defined in a number of ways. Constructability is
described as the optimum use of construction knowledge and experience in planning,
design, procurement, and field operations to achieve overall project objectives
(Constructability, 1986). Constructability is also defined as a measure of the ease or
expediency with which a facility can be constructed (Hugo et al., 1990). Lastly,
constructability is often portrayed as integrating construction knowledge, resources,
2
technology and experience into the engineering and design of a project (Anderson et
al., 1995).
Highway project constructability can be particularly demanding for a range of
reasons. For example, some of the highway construction technologies are varying
hastily, and, as with most construction, the personnel is transient and site conditions
can vary to the highest degree. Nearly all projects are subjected to severe public
scrutiny involving open competitive bidding, thereby separating the planning and
execution phases and largely precluding a fast-tracked approach to construction.
Designs standards, authored by a multitude of organizations abound and often limit,
if not discourage selective innovation. The prerequisite for nonproprietary
specifications often leads to vagueness. In general, the perception is that project
durations are longer than necessary and that construction costs can possibly be
lowered. As a result, specifications supportive of constructability become an
important element for improving project performance (Hugo et al., 1990).
Beside the project performance, constructability also has been successfully
used to reduce project durations. Eldin (1996) provides several examples of projects
that have successfully used constructability to reduce project durations without
increasing project cost. In a CII (1995) study five projects were analyzed, reporting
11 to 30% reductions in project duration directly attributed to constructability
reviews (i.e., without cost increases). Although the majority of the projects were
associated with industrial facilities, one of them was an interstate highway
realignment that included the reconfiguration of eight bridges and the construction of
two new bridges to facilitate the addition of a high occupancy vehicle lane in each
direction (Eldin, 1996).
Constructability review is the phase of construction project management
where an independent and detailed analysis of all the contract drawings and
construction documents is conducted before their release for construction. An
effective constructability review process has the potential to incorporate into design
3
documents the best practices, guidelines, checklist, and lessons learned from
previous projects, thereby improving the ease of construction and reducing life cycle
costs. This critical process evaluates the “ability to construct” your construction
project (Milstead, 1997). Constructability reviews of highway projects during design
have the potential to minimize the number and magnitude of changes and delays
during construction and thereby reduce durations (Anderson and Fisher 1997). A
constructability analysis of six highway projects suggests that benefits may be as
large as 25 times greater as costs (Anderson and Fisher 1997). Improved processes
and management for effectively using constructability reviews to reduce total project
durations can potentially improve construction project management. The way how
to provide the best constructability review is by improving the understanding of
application and importance of constructability concepts in highway projects.
1.2 Problem Statement
Nowadays, highway construction suffers from lack of constructability, which
causes traffic problems, changes of design, poor planning, disputes, cost overruns,
poor safety practices and time delays. Researchers in developed countries have
realized the seriousness of this shortfall and suggested solutions to resolve it. In
Malaysia, research in constructability in highway projects has not been popular
researched yet. One of the reasons is due to lack of understanding of constructability
concepts among the engineers. Design Phase Constructability Improvement
Concepts for Malaysian Highway Projects should be developed, that are aimed at
encouraging the project team to apply them, where appropriate, to their projects. The
basic message is that applying these constructability concepts will enhance project’s
constructability, consequently optimizing the schedule, cost and quality of the project
for the benefit of all parties involved.
4
1.3 Aim and Objectives of The Study
The aim of this study is to establish Design Phase Constructability Guidelines
For Highway Projects in Malaysian Construction Industry. In order to achieve it,
the following objectives have been identified:
a) To identify the constructability concepts in highway projects.
b) To identify the level of importance and application of constructability concepts in
highway projects.
c) To establish Design Phase Constructability Improvement Guidelines for highway
projects.
1.4 Scope of Research
This research was carried out by questionnaires and interviews. The research
focused on Malaysian Highway Projects with contract values of more than RM 5
million. The questionnaires were distributed to the senior construction management
team like engineers, architect or project manager and etc, who involved in highway
projects.
1.5 Research Methodology
The methodology of research were help to realize the essential stages of
methodology performed or steps of process carried in order to achieve the objectives
5
of this research. Figure 1.1 shows the research methodology chart that has been used
in this research.
Figure 1.1 Research Methodology Chart
CONCLUSION/
RECOMMENDATION
CONCEPTUALIZATION
LITERATURE REVIEW
QUESTIONNAIRE
SURVEYS
DATA ANALYSIS
Phase 1 • Design phase constructability
concepts in highway projects
Phase 2 • Level of importance and
application of constructability concepts
• Design Phase Constructability Improvement Guidelines for highway projects.
REFERENCES
Adam, S. (1989). Practical Buildability. The Construction Industry Research and
Information Association, London.
Al-Hammad, A-mohsen and Assaf, S. (1996). Assessment of Work Performance of
Maintenance Contractors In Saudi Arabia. Journal of Management in
Engineering.ASCE. 16(1): 44-49.
Anon (1986). Can Your Design Be Built? Civil Engineering. ASCE: 49-53.
Boyce, W.J. (1991). Design for Constructability. Hydrocarbon Processing. 73(12): 81
CII (1986). Constructability – A Primer. Publication 3-1. Austin, Texas: Construction
Industry Institute.
CIRIA (1983). Buildability: An Assessment. Special Publication 26: CIRIA
David N.Ford, Stuart, and Andrew. (2004). Managing Constructability Reviews to
Reduce Highway Project Durations. Journal of Construction Engineering and
Management, ASCE, Vol. 130, No.1, 33-42
Eldin, N.N. (1996). Constructability Improvements of Project Designs. Journal of
Construction Engineering and Management. ASCE. 114(4): 631-639.
107
Felix, Geogina. (1997). Assessment of Constructability Practices Among General
Contractors. Journal of Construction Engineering and Management, ASCE, Vol. 4,
No.3, 114-123
Fischer, Tatum. (1997). Characteristics of Design Relevent Constructability Knowledge.
Journal of Construction Engineering and Management, ASCE, Vol. 123, No.3, 253-
255
Fisher, D.J. and Rajan, N.(1996). Automated Constructability Analysis of Work-zone
Traffic-Control Planning. Journal of Construction Engineering and Management,
ASCE, Vol. 122, No.1,36-43
Ferguson, I. (1989). Buildability in Practice. London: Mitchell’s Professional Library.
Ganah, A., Anumba, C. and Bouchlaghem, N. (2000). The Use of Visualisation to
Communicate Information to Construction Sites. ARCOM 16th. Annual Conference.
6-8 September. Glasgow Caledonian University, UK: 833-842.
Gambatese, J.A. and McManus, J.F. (1999). Discussion of the Constructibility Review
Process: A Constructor’s Perspective, by Roy Mandelsohn. Journal of Management
in Engineering. ASCE. 15(1): 93-94.
Griffith, A and Sidwell, T. (1995). Constructability in Building and Engineering
Projects. London: Mac Millan Press Ltd.
Hassan, Z. (1997). CONPLAN: Construction Planning and Buildability Evaluation in an
Integrated Intelligence Environment. Department of Surveying, University of
Salford, UK: PhD. Thesis.
Hugo, F., O’Connor, J.T. and Ward, W.V. (1990). Highway Constructability Guide.
Research Project 3-6-88-1149. Centre for Transport Research. Uviversity of Texas.
108
James E. Rowing, Steven L. Kaspar. (1991). Constructability of Cable-Stayed Bridges.
Journal of Construction Engineering and Management, ASCE, Vol. 117, No.2, 259-
275
Jergeas, P.E., John Van Der Put. (2001). Benefits Of Constructability On Construction
Projects. Journal of Construction Engineering and Management, ASCE, Vol. 127,
No.4, 281-290
Kirby, G..J, Douglas, A.F. and Donald, K.H. (1987). Improvement in Design Review
Management. Journal of Construction Engineering and Management, ASCE, Vol.
114, No.1, 549-563
Madelsohn, M. (1997). The Constructability Review Process: A Constructor’s
Perspective. Journal of Management in Engineering. ASCE. 13(3): 17-19.
Nabil A Kartam. (1996). Making Effective Use of Construction Lessons Learned in
Project Life Cycle. Journal of Construction Engineering and Management, ASCE,
Vol. 122, No.1, 14-21
Nima, A.N. (2001). Constructability in the Malaysian Construction Industry., Faculty of
Engineering, UPM, PhD. Thesis.
Nima, Mohd R. Kadir, S. Jaafar. (2002). Constructability Concepts in West Port
Highway In Malaysia. Journal of Construction Engineering and Management,
ASCE, Vol. 128, No.4, 348-356.
Nima, Mohd R. Kadir, S. Jaafar. (2004). Constructability Concepts in Kuala Selangor
Cable-Stayed Bridge In Malaysia. Journal of Construction Engineering and
Management, ASCE, Vol. 130, No.3, 315-321.
109
O’Connor J.T. and Davis, V.S. (1988). Constructability Improvement During Field
Operations. Journal of Construction Engineering and Management. ASCE.
114(4):548-563.
O’Connor, Tamer El-Diraby. (2000). Urban Freeway Reconstruction Planning: Case of
Mockingbird Bridge. Journal of Construction Engineering and Management, ASCE,
Vol. 126, No.1, 61-67.
Philip, Gambatese, James. (2005). Assessing State Transportation Agency
Constructability Implementation. Journal of Construction Engineering and
Management, ASCE, Vol. 131, No.5, 569-578
Rosli Mohamad Zin (2004). Constructability Improvement of Project Design. Dept of
Civil Engineering, UTM, Johor, Ph.D. Thesis.
Russell, J.S. and Gugel, J.G. (1993). Comparison of Two Corporate Constructability
Program. Journal of Construction Engineering and Management. ASCE. 119(4):
771-785.
S.L. Hon, D.A. Gairns, O.D. Wilson. (1988). Buildability: A Research and Practice.
Australian Institute of Building Papers.
Stuart, Fisher, Suhel. (1998). Integrating Constructability Into Project Development: A
Process Approach. Journal of Construction Engineering and Management, ASCE,
Vol. 126, No.2, 81-88.
Stuart, Fisher, Suhel. (1999). Constructability Issues In Highway Projects. Journal of
Construction Engineering and Management, ASCE, Vol. 15, No.3, 60-68.
Thomas E. Glavinich. (1995). Improving Constructability During Design Phase. Journal
of Construction Engineering and Management, ASCE, Vol. 1, No.2.73-76.