SCHOOL OF ARCHITECTURE, BUILDING & DESIGN

BACHELOR OF QUANTITY SURVEYING (HONOURS)

BLD61103 INDUSTRIALISED BUILDING SYSTEM (IBS)

FACTORY VISIT ASSIGNMENT

In association with:

GROUP MEMBERS:

Enoch Ang Ee Nok (0318965)

Joshua Chua Shu Min (0313572)

Muhammad Haziq Bin Hj Zariful (0314131)

Thean Hai Xu (0313489)

LECTURER:

Miss Theong May Chuan

SUBMISSION DATE: 9th June 2015

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TABLE OF CONTENT

1.0 Introduction 3-5

1.1 Formation

1.2 History

1.3 Services

1.4 Notable Projects

2.0 Industrialized Building System 6-10

2.1 Swissma Products

2.2 SANKO Products

2.3 Installation of Dopplewelt Standing Seam

2.4 Installation of Snapwelt Roofing System

3.0 Manufacturing Process 11-14

3.1 Sanko Production Site

3.2 Swissma Production Site

4.0 Contributions of Swissma to the Construction Industry

15-16

5.0 Conclusion 17

References 18

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1.0 INTRODUCTION

1.1 Formation

Before its formation in 1997, Putrajaya needed to build the Prime Minister’s house that

requires the use of high tech material, titanium zinc, a product from France. However,

Malaysia did not have the technology or manpower to do so.

Eventually the Malaysian construction company was able to find a group of Swiss master-

craftsmen who can provide the elimination of obstacles to be able to provide high-end

premium roof and wall cladding systems and hence they came together as Swissma was

born.

1.2 History

After Swissma as formed in 1997, the first project they landed was the Prime Minister’s

house in Putrajaya. In the year 2002, Swissma was called to partner & become a

subsidiary of Swissma by a company called Association Steel Industries Malaysia Sdn

Bhd (ASIM), an established and highly reputable company that has been in Malaysia since

1974 that mainly focuses on manufacturing metal sheets used for institutions, factories,

warehouses and the like. Whereas Swissma is a company doing custom made solution,

doing most of the high end and tailor made solutions, hence with the additional provision

and partnership of ASIM, they are able to enlarge their scope on metal roof solutions.

Adding to the fact, ASIM is a brand under SANKO, which is a very big Japanese metal

company in Japan, hence, Swissma not only has a larger scope on metal roof solutions

but also enlarges their skills by acquiring both Swiss & Japanese elements into their

company. These advantages along with their own excellence has given Swissma a large

reputation to be made official supplier and installer by numerous international

manufacturing corporations & hence has established Swissma as Malaysia’s dominant

total solutions provider for roof and wall cladding.

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1.3 Services

Swissma is a solution provider in many different types of metal roofing and cladding. The

company’s services are divided into 3: Design, Fabrication & Installation, each having their

separate departments in the company. The designing department goes hand in hand with

designers, architects and quantity surveyors to design requests. The fabrication

department is located in the factories to form out the tailor made façade cladding using the

wide range of metal materials they have provided by SANKO and Swissma. The

installation team carries out the installation jobs, sometimes in certain circumstances

having an office on site.

1.4 Notable Projects

Setia Convention Centre Swissma Standing Seam Roofing System in Colorbond steel.

Universiti Tunku Abdul Rahman(UTAR), Perak Swissma Doppelwelt Standing Seam in PVDF-coated Aluminium.

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Aviatron Factory, Penang Swissma Casex Cladding and Swissma Zipwelt Standing Seam Roof in Clean Colorbond Steel

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Bungalows in USJ 1 Sanko Grip Deck 3-Pan in Clean Colorbond steel.

Persada Johor, Johor Swissma Standing Seam in Clean Colorbond steel.

2.0 IBS COMPONENTS2.1 Swissma Building Technologies Sdn. Bhd. Products

PRODUCTS DESCRIPTIONS

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Figure : Swissma Doppletwelt Standing Seam

Image retrieved from

http://www.swissma.com/v1/product/swismaproduct/03.swf

Swissma Dopplet Standing Seam is an adaptable roofing profile

that has double seamed joints in order to have a refined and shiny

appearance for architectural purpose.

Features :

(i) It is concealed with sliding fixing system is to allow it to

adapt to the thermal changes.

(ii) The seaming of the joints has also furnished it by making it

completely leak proof.

(iii) The distinctive feature is that, it complemented by a full

range of custom made accessories, which fulfill most

convoluted details by following international standards.

Applications:

(i) Roofing

(ii) Soffit

(iii) Siding

Figure : Swissma Rollcap Batten Seam

Image retrieved fromhttp://www.swissma.com/v1/

product/swismaproduct/04.swf

Swissma Rollcap Batten Seam is a classical roofing profile with

a specific designed click on capping joint which provides a linear

as well as gallant surfacing.

Applications:

(i) Roofing

(ii) Wall Cladding

Figure : Swissma Dach Metal Tiles

Image retrieved fromhttp://

www.swissma.com/v1/product/

swismaproduct/01.swf

Swissma Dach Metal Tiles are large speacially crafted with flat

seam joints to create an ideal option for innovational and high

quality design.

Application:

(i) Roofing

PRODUCTS DESCRIPTIONS

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Figure: Astana AS760Image retrieved from

http://www.swissma.com/v1/product/sanko/AS760.swf

Features:

(i) For lengths exceeding the permitted normal

transportation, roofing profile can be formed on site

to prevent end lapping

(ii) It can also be easily installed using self- drilling

screws with neoprene washers.

Application:

(i) All types of buildings

Figure: Sanko SK RIB 38 II

Image retrieved from

http://www.swissma.com/v1/product/sanko/SK

%20RIB38.swf

Features:

(i) Its high corrugations can oblige to very low pitch as it

has the ability to span far hence purlin cost can be

saved.

(ii) For lengths exceeding the permitted normal

transportation, roofing profile can be formed on site

to prevent end lapping

(iii) It can also be easily installed using self- drilling

screws with neoprene washers.

Application:

(i) All types of buildings

Figure: Gripseal S-63

Sanko Gripseal S-63 is a boltless roofing profile which utilizes

the distinctive concealed fixing method by attaching each rib to

the clips fixed on a concealed roof connector.

Features:

(i) The distinctive concealed fixing method has result in

strong fastening of roofing sheets which prevents

wind uplift completely.

(ii) A boltless and non-punctured roof surface has allow

it to eliminate water penetration.

(iii) The simple positive locking method also reduces

labour cost and overall construction cost.

Application:

(i) Used in cost conscious building industry.

2.2 Sanko Products

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2.3 Installation of Swissma Doppletwelt Standing Seam

Step 1:

The

installation

starts by

placing a

starter

piece on

the roof including the indicating of checkpoints.

The fold end of the top plate is being ensured

that it is placed directly to the bottom plate to

prevent any air gaps between the bottom panel

and top panel.

Step 2:

The position of the starter panel is being

double checked again by ensuring both lengths

of the sides are equivalent.

Step 3:

The sliding clip is being placed at every 600mm.

After the position of it has been indicated, it is then

being screwed to the bottom panel.

The picture on the left shows a close up of a sliding clip. It is

being used to manage the thermal expansion, which will cause

the roof to curve up if there is no allowance for it. Galvanized

nails are also being used in this case as it is being exposed to

high corrosion rate.

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Step 4:

The next panel is being placed by linking both

middle parts of the starter panel together and

covering the sliding clips that were being placed as

shown in Step 3.

Step 5:

Single seaming tool handles is then being

stretched to a span of approximately 180 degrees

in order to fold the top two panels.

Step 6:

As for the last step, it is to do double seaming

to both panels together so that it can prevent

water from passing through easily. If the joints

are not connected properly, it is also not

advisable to refold them, as it will break them.

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2.4 Installation of Swissma Snapwelt Roofing System

Step 1:

The starter piece is being placed at the side as the starting point. It

is a 90 degrees bend panel.

Step 2:

Nailing one side of the roof panel is taken place next. The reason

why foam is placed underneath the roof is to dampens the noise

and provide thermal insulation for the building.

Step 3:

The next panel is then placed beside the starter panel by

overlapping it.

Step 4:

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The final step is to step on the top overlapping parts of the panels on the roof in order to fix

it. Snapwelt Roofing system cannot do curve roofs but only straight roofs. Therefore, it is

cheaper.

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3.0 MANUFACTURING PROCESS

3.1 Sanko Production Site

High end product is manufactured by Sanko production site. The size of the metal roofing

sheet fixed at 600mm width due to the coil size ordered by Swissma. Two main

manufacturing process involve in this site are roll formed and crimping of the metal roofing.

ROLL FORMING TECHNIQUE:

Figure: Roll Forming MachineImage retrieved from

http://www.coldrollformingmachine.org/rfmnews3/machine457.html

Roll forming is a cold roll process which progressively shapes the sheet metal by passing it

through a series of roller (roller die) in the rolling machine. The metal sheet is released by

the decoiler at the end of machine before passing through the roller. Various shape and

size of roller is used in different position to form the desired cross section. The rolling

process is slowly forced the sheet metal from outward to inward after each roll station

instead of the other way round.

Figure: Roll-Forming ProcessImage retrieved from

http://www.custompartnet.com/wu/sheet-metal-forming

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The reason is because rolling operation will cause increase in width and reduction in

thickness. If the sheet metal is pushing from inward to outward, the forming process might

deform the final product as there is no allowance for the inner part to spread when forcing

outward and worst it may snap. After the bending done, the sheet metal will be cut off and

proceed to the next panel. Besides, each roller dies are lubricated to minimize the friction

and reduce the tool wear throughout the series of bending operations. The desired length,

numbers and shapes of the metal roofing is able to monitor by the computing system

(encoder). Hence, the overall manufacturing process is consistence, effectiveness, time-

saving and economical as it reduces the possibility of wastage generation by high

accuracy and quality which only allowing 6mm tolerance.

CRIMPING TECHNIQUE:

Figure: Crimping Machine

Image retrieved from

http://willing.en.alibaba.com/product/760016021218056600/roof_sheet_crimping_machine.html

Crimp curve roofing is popular used for bus shelter, parking and edge of building due to its

curvature design which eliminate the gutter and ease for installation work. In addition, it is

anti-corrosion and high durability thus able to withstand weather battering. Crimping

machine contains hydraulic crimping mold which used to form the crimp of the metal panel.

The radius of the curve arch depends on the crimp size formed; the bigger the crimp, the

bigger the radius of the roofing and vice versa. Each crimp mush be constant and

identical, if one of the metal roofing unable to stack well, it indicates there is differences of

crimp size for that particular panel.

Figure : Crimping Curve Roof14

3.2 Swissma Production Site

Unlike Sanko site, Swissma site provided tailor or custom made roofing services. The

width of the panel manufactured can vary from 200mm to 900mm. They are able to form

tapered shape, continuous curving roof without crimping and three dimensional bending

which the Sanko site cannot perform. Every panel is prefabricated which minimizes the

amount of site work and reduce the manpower on the site.

TAPER CUT TECHNIQUE:

Automatic taper sheet slitting machine is available in this site to cut the metal sheet into

taper shape. In order to do so, the operator only needs to set the base and top length into

the monitor; then the machine will automatically cut out the correct angle. However,

several considerations have to be taken especially in term of costing. Contractor may incur

additional cost for the taper sheet as the remaining part of the metal sheet will count as

wastage if it is not proper designed.

3D BENDING & FOLDING:

Figure: 3D Bending & Folding Machine

Image retrieved from

http://www.schroedergroup.eu/en/products/bending/mpb.html

Swissma company adopted and implemented the technique of Schroder MPB folding

machine with assist of POS 2000 graphic controller for bending and folding process. This

machine allows users to form any shape that had been saved in the integrated database

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and touch display is available to guide the users throughout the folding process. Once the

type of roofing is decided, the machine will automatically measure the metal sheet, fold at

the right angle and position and complete for the whole roofing step by step. High quality

and productivity is guaranteed due to its extremely high precision and operational speed.

EDGE PREPARATION:

Figure: Close Up Look of Edge Preparation

This manufacturing process involves three steps, which are bending, flattening and folding.

In this case, a special machine has been used as it is able to cover all process of the edge

preparation for the roofing panel. The end edge of the two sides of the panel will be cutoff

first which allowed the machine to bend and flatten the end edge. Then the panel will be

folded down to form a drip edge for the installation purpose.

Figure: Air Gaps while Stacking

Air gaps are being created to break the capillary actions to prevent water from seeping in to the roof panels.

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4.0 CONTRIBUTIONS OF SWISSMA TO THE CONSTRUCTION INDUSTRY

Swissma’s products are in line with what IBS seek to improve in the construction industry, making a significant contribution being one of their company’s key goals. These contributions to the industry are discussed in detail below:

(a) Reduced construction time and cost, and faster installationConventional construction methods require a huge amount of in-situ construction works. Swissma’s products are being manufactured in their factory, which is then transported to the site and are ready to be erected and assembled together. It is more efficient than in-situ works, speeding up any projects that Swissma are being contracted to work with.

(b) Reduced energy and workforceBeing one of the more general offerings that IBS has to offer, Swissma’s products are being worked on by skilled and experienced workers only in their manufacturing factory, and also on-site installation process, eliminating any need of extra labour.

(c) AestheticsSwissma’s range of products are designed to be architecturally and aesthetically pleasing.

(d) Prefabrication in a controlled factory environmentBeing manufactured in a controlled environment, Swissma have high quality control, leading to products that integrate quality and consistency. Their metal roof and accessories are cut to the precise length and size exactly to their client’s requirements and specification.

(e) Swissma’s products can be reused and recycled, have high sustainability, and are environmentally friendlyThis is in relation to waste control. Swissma will minimize on-site waste. Their steel building components that are wasted can be reused and recycled into the same quality, and is inherent to sustainability at this phase of a development’s life. No off-cuts need to be disposed off in landfills. This will lead to reduced consumption of raw materials, and also will reduce greenhouse gas emissions as compared to any virgin production.

(f) Swissma’s products are durableSteel products have a long lifespan and require minimum maintenance when compared to alternative options that are shorter lived that are used for the same purpose, therefore increasing its overall sustainability. Besides, steel require fewer resources spent on maintenance and replacement.

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(g) Better supervision on improving the quality of their productsSwissma’s prefabricated products can achieve better quality product by having better supervision, as their products are tested and inspected before site installation.

(h) Enhanced occupational health and safety recordsSwissma adheres to stringent protocols, regulations and requirements during the manufacturing process as well as during site installation.

(i) Lightweight transportation and constructionSteel is lightweight compared to many other materials used for the same purpose. Hence, their steel components can be easily lifted into place, thus reducing the need for heavy cranes. Lightweight steel roof also require less roof framing than a heavier roofing material. This in turn will lead to less damage to site, reduced landscaping costs, and less disruption of nearby built and natural environment, such as noise, traffic and sedimentation.

(j) Standardized productsNot only does Swissma cater to specific client requirements, they also have standardized products. Standardization can achieve better performance and cost reduction. Time can also be reduced as the prefabrication can increase the productivity and efficiency of building construction.

(k) QLASSICQuality Assessment System in Construction (QLASSIC) is a system or method to measure and evaluate the workmanship quality of a building construction work based on Construction Industry Standard (CIDB 2015). Swissma has contributed more than 70% to this assessment in Category B (Stratified Housing), mainly in structural, architectural and external works with their steel products.

(l) Customer satisfactionWith all of the aforementioned points above, Swissma’s products offer a very high customer value-for-money, and overall satisfaction.

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5.0 CONCLUSION

Figure: A Group Photo of Us

Not only that, to gain trust from their customers, they also encourage the clients and architect to witness the demo so that they are able to have a clearer picture of the roofing system by explaining it to them. Henceforth, if anything goes wrong, they are able to know where to find the solution.

The Site visit has benefited us all as we have gained experience, knowledge and understanding on Metal Roofing through Swissma’s thorough teaching on both theory and practical information during the visit. Educating us from the basics such as the materials used to the very specific knowledge such as the step-by-step installation process.

Currently, Swissma is doing the MRT station roof along the Cheras area. The company hopes to continue their competition is the market as Malaysia’s leading total solutions provider & complete many projects to achieve their vision of becoming a leading global provider of total roof and wall cladding solutions.

As a part of Taylor's University, we would like to extend our gratitude for your great hospitality throughout the half-day visit in Swissma Building Technologies Sdn Bhd. We would also like to thank Alex Pang & Peter Kho for presenting us on theory and practical knowledge on metal roofing respectively.

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