CHAPTER 1

INTRODUCTION

1.1

Introduction to the Research

This report will discuss about the ground floor slab construction by using used
tyres (Smart and Cool Home System). The purpose of using tyres as the ground floor slab
according to the inventor, Mr. Lincoln Lee, is to cooling the interior building without
using air-conditioning whereby the tyres can absorb heat from the outside. This system
has been implemented to a few houses in Malaysia. The result is mesmerizing whereby
the interior side of the house is cooler as compared to normal house.

1.2

Research Title Selection

For a commercial building, the management normally has to spend about 30%60% on electricity only for cooling down their building. Further more the usage plenty
numbers of air-conditioning can cause air pollution. To overcome this problem, the
management needs to consider using other cooling method. Thus, Mainstay Development
has decided to use used tyres as the ground floor slab (Smart and Cool Home System) as
it may reduce or sink heat from outside before the heat enters the building. So, the main
reason to select this research title is that, to study on the technology and to test either this
method is effective or not.

1.3

Research Objectives

The objective of doing this report is to learn and to understand with theory and
reality on site on how to construct concrete ground floor by using used tyres which had
been used at the space u8 project. Some objectives of doing this report are:
i.
ii.

To learn the process of constructing concrete ground slab by using used tyres.
To understand the system and the function of concrete ground slab by using used

iii.

tyres.
To identify problem occurred and will occur in the process of constructing this
type of slab.

1.4

Research Scope

This research has been done on Space U8 located at Bukit Jelutong, Shah Alam,
Selangor, through out six month period on site. This report is focusing more on the
ground floor slab construction especially on grid line 24-37/A-D. As the project is using
used tyre for the ground floor slab, so, research has been done on the tyre especially on
the number of tyre used, the system and the functions.

Scope area
Figure 1.1: floor plan

1.5

Research Methodology

In order to complete this report, a few method had been done, which are:i.

Primary data
a. Observation
Observation had been done through 6month duration from 18 th of May
2009 until 20th of November 2009 at site located at Bukit Jelutong, Shah
Alam, Selangor. From the beginning, its been observed that the location,
calculation and arrangement of tyres are being placed according to plan as
it is the first ever building using tyre as foundation. They engaged
qualified Engineer and Site Supervisor in order to ensure its according to
plan. Normally, for an area of 30 x 30 meter, they engage approximately
25 workers to setting up the base, arranging the tyres, fabricating bar and
concreting the slab.
b. Interview
The smart and cool home system inventor (Lucas Sdn. Bhd.).
Mr. Lee from Lucas Sdn. Bhd. is the inventor of this smart and cool
system. Mr. Lee informed that this system can help to reduce heat in a
building in other words it can maintain the coolness of the building. He
also emphasize that this cooling system has been tested in his warehouse
and it really reduce the heat in the warehouse.
General Manager (H&I Niaga Sdn. Bhd)
En. Roslan claims that this is a very good system since we could recycle
used tyres into something useful and on the other hand it can helps to
reduce heat in the building. He also informed that there are two process of
constructing the slab which is monolithic and non-monolithic.

Clerk of work (KTA Tenaga Sdn. Bhd.)

En. Mazlan and Mr. Jerry inform that, since this system is a new system
concept, a thorough inspection need to be done at all time.
ii.

Secondary data
Generally, data collection technique is taken via journals, reference books,
articles, and newspaper cutting. These refer as general knowledge which is a
theoretical research or known as study case. Besides that, data collection via
internets also use as research methodology because collection data via internet is
faster if compare to other technique. Furthermore, the information is updated
depending on the environment issue.

CHAPTER 2

COMPANY BACKGROUND

2.1

Introduction

Mainstay Development Sdn Bhd is a subsidiary of Mainstay Holdings Sdn Bhd.

The property arm is led and managed by a group of multi-disciplined professionals with
collective experience of more than 100 years in managing public listed companies and
property development. Addressing at Plaza Danau 2, Taman Danau Desa, Kuala Lumpur,
Mainstay Development Sdn Bhd, always look forward for comfort and conducive
construction and at the same time earth friendly. Thus, this company has implemented
many new technologies for their project. For example, at the Space U8 project, their
first project, they had implemented the Smart and Cool Homes system.

Figure 2.1: company logo

66M
5A
%N

I
S

Y
H
O
D
N
G
SS

L
I
S
DD

N
B
D

Chart 2.1: company structure

2.2

Company History
Mainstay Development Sdn. Bhd. was established on 13 th of December 2006. The

company executive director, Raja Azmi Raja Razali was previously the Chief Executive
Officer of Fly Asian Xpress Sdn Bhd (FAX), now officially renamed AirAsia X untill
June 2007. Soon after, he changed to developers sector. He has established Mainstay
Developers Sdn Bhd. At the early year of establishment, the company only has one
director, Dato Zakaria Meranum. Then, at the middle year, Ang Teck Seong and Teo
Swee Phin have joined the company to build the company become stronger. Different
from other developers company, Mainstay Development hired project manager to
manage, conduct and to control their project on site. Previously, they only rent a shop lot
as their company office located in Subang. Now, they manage to buy their own office
building which is located in Kuala Lumpur.

2.3

Company Objectives

Same like other developers company, Mainstay development aims to target yearly
projected turnover as follows;
i.
ii.
iii.
iv.
v.

2007 RM 15,000,000
2008 - RM 30,000,000
2009 RM 50,000,000
2010 RM 70,000,000
2011 RM 85,000,000

This company also aims to be number one Malaysias developers company which
concern about mother earth.

2.4

Organisation Chart

Photo 2.1: Mainstay Development management team.

From left, Ang Teck Seong, Raja Mohd Azmi Raja Razali, Terry Teo Swee Leng, Lee
Swee Phin, Dato Zakaria Meranum and Hasnan Saidin

E
D
D
P
SC
iaxeir
rlcpE
o
estue
cOvyut
tfC
vM
oihaO
reianf
m
r
rae
a
m
g
ae
n

e
e

h
f

u
i

f
c
r i
r

e t
e
a
i c

i
f

r
Chart 2.2: Mainstay Development organization chart

2.5

List of Project Done To Date

No

Project title

.
1.

CADANGAN

contract
duration
PUSAT 1 year and

MENDIRIKAN

PERNIAGAAN YANG MENGANDUNGI:i.

ii.

232 UNIT KEDAI PEJABAT STRATA;

1 UNIT KOMPLEKS PERNIAGAAN 4

iii.
iv.

TINGKAT
1 UNIT RUMAH SAMPAH
3 UNIT SUBSTESEN ELEKTRIK

6 months

DI NO.6 (LOT PT 33313), PERSIARAN PASAK

BUMI, TAMAN BUKIT JELUTONG, SEKSYEN
U8,

SHAH

ALAM,

SELANGOR

UNTUK

TETUAN MAINSTAY DEVELOPMENT SDN.

BHD.
Table 2.1: List of project done to date

10

Contract price
RM84 million

CHAPTER 3

THE SMART AND COOL HOMES SYSTEM

3.1

Introduction

Air-conditioning systems are increasingly seen as a part of the climate change

problem, as well as its solution. Not only is the rising cost of energy a problem, but the
energy used to run these systems is a major contributor to greenhouse gas emissions.
Smart and cool homes system aims to create a new cool vernacular building approach,
which matches human and environmental needs and so to overcome above problem. The
smart and cool home system can be implemented for the roof, wall and to the floor.

3.2

The Smart and Cool Homes System for Roof

Roofing can contribute to energy efficiency in two ways; proper insulation, and
reflective surfaces. Proper insulation helps keep warm air out during the hot day.
Insulation needs vary from climate to climate, and most local building codes today
mandate minimum roofing R-values (a materials ability to resist heat flow). Here is a
short list of important factors to consider when selecting a cool roofing system:
i.

Reflectance/emittance performance, both initial and after three years.

ii.

Long-term track record of durability and performance.

iii.

A good warranty backed by a solid, well-established manufacturer.

11

iv.

Climate and weather extremes in a given location

3.2.1

White Coated Roof (Cool Roof)

This system was invented in Philadelphia by a company called ECAs Smart

Homes. The goal is to reduce indoor air temperatures to comfortable levels
without increasing the occupants' energy bills by maximizing passive cooling and
ventilation and minimizing mechanical cooling. The treatments start with a white,
acrylic elastomeric roof coating, additional insulation, air sealing, and others.

Photo 3.1: Right shows the white coated roof

A black or dark colored roof absorbs the energy from the sun's rays and becomes
extremely hot. On a hot day, a black asphalt roof con reach 195F. Much of this
heat can radiate to the inside of the building. In their webpage,
www.ecasavesenergy.org, stated that white roof coatings reflect the sun's rays and
can help to reduce air-conditioning bills by 22% on average.

12

Figure 3.1: Sun rays reflection.

Source: http://asusmart.com/

Asphalt, dark roofed and dark buildings absorb heat. Rooftop heat can reach over
190F. All of these dark surfaces absorbing and letting off heat in the city cause
the urban heat island effect. Summers in the city are typically 5-10 degrees
warmer than in the surrounding countryside. Figure below shows temperature
reading for black roof as compared to white coated roof.

13

Photo 3.2: 138F black roof on a hot summer day

Source: http://www.ecasavesenergy.org/

Photo 3.3: 89F the same roof with white coat

Source: http://www.ecasavesenergy.org/
The result shows that, the white coated roof is much cooler then the black roof.
Thus, it can be concluded that, by using white coated roof, it can cooling down
interior temperature of a building.
3.2.2

Green Roof

A green roof is a roof that has vegetation growing on it, which could be as simple
as grass, or as complex as a whole garden or ecosystem. Green roofs are
considered extensive if they contain 3 to 6 inches of soil substrate, enabling the
growth of a basic variety of plants, generally sedums. They are considered
intensive if they contain 6 to 12 inches of soil substrate, enabling a larger variety
of plants to grow. Green roofs are relatively new in the United States, the
technology has already been widely adopted in Europe. Modern green roofs have
been constructed in Germany and Holland for more than 40 years.
14

Plant species are selected that have properties such as shallow root systems, good
regenerative qualities, resistance to direct solar radiation, drought, frost and wind.
Vegetative cover can consist of a thin layer of moss and lichens to an assortment
of native grasses, shrubs or even intricately landscaped gardens with multiple
species and a soil substrate of 6 inches or more. Green roof top covers can be
found atop anything from low density residential dwellings in rural settings, to
commercial, institutional and even large-scale industrial sites of at least 10 acres.

It is the desired function of the roof space that usually drives the green roof
design, resulting in designs requiring different soil depths to accommodate
various plants, shrubs and trees. The additional structural support necessary to
accommodate higher roof loads must also be taken into consideration.

15

Figure 3.2: Cross-section of a green roof system

Referring to figure above, a waterproof membrane installed at top of the

existing roof, followed by a root barrier, a layer of insulation (optional), a
drainage layer, applied over the entire roof area. The drainage layer is present to
carry away excess water. On very shallow extensive green roofs the drainage
layer may be combined with the filter layer. A filter fabric for fine soils, the
engineered growing medium or soil substrate (minimum of 2.5 to 3 inches to
support a diverse and healthy plant community) and finally the actual plants.
Additional items can include a "wind blanket," such as a jute or coco liner-type
mesh, to help stabilize and establish the roots of the new plants, as well
as measures to prevent shearing and erosion on roofs of 20 or more. Measures
on steep roofs include the installation of additional support with cross battens. A
raised grid structure is installed to secure the growing substrate. A shallow layer
of gravel or pebbles are placed from 18" to three feet within the outside
perimeter of the roof to provide for additional drainage, fire control and roof
access.

Photo 3.4: Fukuoka Prefectural International Hall in Fukuoka, Japan

16

Figure 3.3: heat island effect

Source: www.asusmart.com

Photo 3.4 shows example of building that used green roof system. It was located
in Japan. Figure 3.3 shows the heat island effect. Temperature is maximum
around urban area. It is due to lack of vegetation. Lack of vegetation can cause
pollution to the surrounding area. Vegetation helps to reduce the amount of
carbon dioxide produce by vehicles, machines and such. As can see from the
figure 3.3, agriculture area has the lowest temperature reading.

As global warming becomes more and more of an issue, and towns and cities
expand, green space is becoming more and more important. Green roofs are
particularly useful at filtering out pollutants from the air and as such, purifying it.
This ensures a greater quality of life for everybody. Green roofs also provide
many other advantages over a traditional roofing system. Other advantages are:
i.

Roof Water conservation

Green roofs trap and use rainfall and other moisture from the air. This
prevents excess water run-off from home that travels into storm drainage
17

systems. Many towns storm water treatment facilities are overwhelmed

and cannot efficiently process and treat the water that is being contained
and constantly replenished. If storm water cannot enter these treatment
facilities it flows into lakes, rivers, and other waterways leading to
flooding and pollution.
ii.

Roof Temperature control

A green roof is an added layer of protection of our home from the outside
elements. Thus, it forms another insulation barrier helping keep hot
temperatures out in the summer and cool temperatures out in the winter.
Our home will maintain a more constant temperature with your airconditioning system working less, thus saving our money on utility bills.

iii.

Roof Soundproofing
Because of this added layer of protection a green roof provides our home,
it can also act as a sound barrier by muffling outside noises. If our home is
by a busy highway, a shopping center, or airport, we will notice a
significant sound reduction by installing a green roof. The natural
elements of this roofing system will trap and disburse sound, making our
home quieter.

iv.

Roofing Repair costs

A green roof will protect the material that is underneath, often extending
the average lifespan of the roof by many years. This is because it will not
be directly exposed to the elements and weather conditions. The several
layers a green roof is comprised of, including waterproofing membrane,
soil, mulch and plants themselves all provide additional protection. Roofs

18

can cost several thousands to repair or replace, so a green roof can save us
a significant amount of money over the long haul.
v.

Roof Aesthetics
Many homeowners who install them do so because of the beauty it can
bring to a home. Ideas and options are limitless, only hemmed in by our
creativity. A professional roofing contractor can help us to choose
plantings based on their color, season and growth cycle. You can also
change your plantings from season to season or year to year, depending on
your taste.

Figure 3.4: Storm water management

Source: http://commons.bcit.ca/greenroof/faq.html

Whilst there are many advantages of green roof technology, it is important to

consider and review the disadvantages.
i.

Imposed Loads
Irrespective of whether "intensive" or "extensive" roof solutions are
adopted, green roof constructions impose greater loads than more

19

conventional roofing systems and therefore require stronger supporting

structures and foundations.

ii.

Roof Leaks
Roof membrane failure in green roof systems has been a major cause of
reluctance to adopt this form of alternative construction and modern
technology has endeavored to reduce the incidence of failure. However,
failure of the waterproof membrane due to faulty materials and
workmanship, or root damage, remains as a significant problem.

iii.

Maintenance
Compared against conventional horticultural schemes such as manicured
lawns and planting beds, extensive green roof solutions can be considered
as relatively low maintenance. However, when compared against
conventional roofing solutions, the input required is exceptionally high.
Particular attention is required during periods of initial establishment,
when seeds and plants will require regular irrigation, weeding and feeding
with an appropriate release fertilizer. Once established, maintenance levels
can be reduced, but regular weeding, trimming, irrigation during drought
conditions and general husbandry is an essential legacy. In order to
comply with the statutory requirements of the CDM regulations in respect
to roof access etc. additional cost would be attracted in the provision of
sophisticated safety access equipment.

iv.

Fire Load
Unless a scheme is provided with an expensive automatic irrigation
system, green roof planting can die back in periods of extreme drought
20

and present a serious additional fire load and arson target. This is
particularly relevant to the use of grasses and mosses, which are highly
dependant upon regular irrigation to sustain chlorophyll levels.
v.

Wildlife Infestation
Whilst promoters of green roof concepts herald the attraction of birds and
butterflies as a benefit of this form of environmental technology, green
roof systems are not necessarily selective in their attraction properties and
can serve to entice some forms of wildlife which may be considered as a
nuisance by building occupants.

vi.

Cost Considerations
Due to the composite nature of the roof build up, additional structural
requirements and labour intensive construction and maintenance elements,
green roof installations are generally considered to be more expensive than
alternative conventional roof constructions. "Spons" price guide 2003,
advises that initial cost for a landscaped roof finish would be in the range
of 134 -163/M2 compared with 26 - 30/M2 for a conventional three
layer, high performance felt system. These cost estimates are for the roof
finish only and make no allowance for any additional structural
requirements to support the additional loads.

3.2.3

Photovoltaic roof

One option is the use of a photovoltaic (PV) roof system. Large PV panels,
mounted to residential roofs, are very common, especially in the southwestern
states. These panels are often unattractive, bulky, and expensive. However, recent
breakthroughs in PV design and technology have produced PV modules that
21

replace conventional roof tiles. They come in all shapes, sizes, and varieties and
can be used in both residential and commercial applications. PV preserves the
earth's finite fossil-fuel. Resources; coal, oil, natural gas and reduces air and noise
pollution associated with these energy sources. Also, depending upon where some
user live and taking into account current utility pricing, state and local incentives
offered in some parts of the United States, and other benefits, PV can be
competitively priced with traditional energy sources. Also, PV system reliability
and durability are outstanding. Typical PV systems may last 30 years with
minimal maintenance.
A typical PV system consists of solar cells connected electrically to form a
module, which in this case would be a single roofing shingle. All of the shingles
connected together make up an array. Since the electricity generated by these PV
arrays is direct current, an inverter must be used to convert the electricity to
alternating current. Batteries may also be added for emergency backup in the
event of power outages or in cases where your PV system is not connected to
utility power lines. If you do choose and are able to connect the system to the
power lines, it is possible to generate electricity for your power provider and
actually make a profit from the system.
The amount of electricity produced by a PV system is based primarily on the size
of the system, but the output of the array will depend on the following:
i.
ii.
iii.
iv.
v.
vi.

Geographic orientation
Amount of sunlight available at the location
Tilt angle from horizontal
Azimuth orientation with respect to due south
Shadowing
Temperature

Other considerations not affecting the system itself include local utility rates, tax
credits, and maintenance.

22

Design of the systems is fairly simple since there are very few components. The
major design issue is likely deciding the size of system that will be used. From a
construction standpoint, PV roofing systems are easy and ready to install and
supplied by numerous distributors. PV roofing installations require a portion of
the roof to be exposed by direct sunlight. For North America this would be a south
facing exposure, usually on an inclined roof. Depending on the product, it can be
installed by roofing professional, an electrician, or both. In some cases the
manufacturer will also provide installation.
Even though PV roof shingles are fairly new, there are several different types that
can be used for various applications. Pictured below are just a few of the different
types available:

Photo 3.5: shingled roof

23

Photo 3.6: metal roof

Photo 3.7: flat roof panels

One disadvantage of a PV system is its high initial cost. A rooftop integrated PV
system fully installed costs approximately RM 45,000 - 60,000, depending on the
size of the system. This is approximately 18-25 per kilowatt hour, which is
significantly more than conventional grid-connected power. But, when
considering environmental benefits and available grants and tax incentives, a PV
roof system can be comparable to the cost of conventional grid connected power.

24

3.3

The Smart and Cool Homes System for Wall

Walls plays important rule for a building interior temperature as the wall is an

exposed element for a building. Selecting a correct types of bricks may resulting a
mesmerizing condition of the interior building where by it may helps to reduce to up to
5C. Thus, many people in the world nowadays have invented many types of bricks
which may helps to reduce or absorb heat.

3.3.1

Calcium Silicate Bricks

Sleek, sharp and strong are the characteristic of calcium silicate bricks.
Internationally renowned for their high comprehensive strength, quality and
aesthetic value, controlled by a British Standard 187, calcium bricks have proven
their superiority over other kinds of building materials. Yet they are superiority
priced to enable home owners the opportunities of experiencing their remarkable
advantages.
Calcium Silicate Bricks are made by compressing a mixture of naturally clean raw
materials, lime and sand, under high pressure steam; a process which chemically
fuses the raw materials to form calcium silicate, a compound that is well known
for its heat insulation property. The lime and sand used is tested for consistency,
fineness and purity. During the process of manufacturing, below par bricks are
automatically destroyed. The final product is subject to impact tests to verify its
strength.

25

Photo 3.8: calcium silicate bricks

Source from the Calcium Silicate Bricks (KALSA) pamphlet, calcium silicate
bricks offer a few distinct advantages, which are:i.

Beauty
In their natural state, Calcium Silicate Bricks are white; a whiteness that
remains even through years of weathering. By pre-mixing with pigments,
Calcium Silicate Bricks of almost any colour can also be produced. This
together with their perfect geometrical shape, uniformity in size and
aesthetic appeal make Calcium Silicate Bricks most suitable as a
decorative medium in home construction or as facing bricks.

ii.

Economy
Their uniform size and shape enable easier and fast bricklaying. Being
hard, damage by rough handling on site is only minimal. This give saving
in terms of materials, labour, time and cost.

iii.

High Compressive Strength

Compacted and steam-cured at high temperatures and pressures makes it
posses high compressive strength, together with the load-bearing

iv.

capability, Calcium Silicate Bricks are ideal for none-frame construction.

Heat Resistance

26

Calcium Silicate Bricks have exceptional heat insulation characteristics,

thus ensuring a cool, crisp interior for more comfort.
v.

Sound Insulation
Their sound insulation property keeps us working and living environment
quiet and peaceful.

vi.

Durability
Calcium Silicate Bricks harden with age. As they do not contain soluble
salts, they do not effloresce or deteriorate.
Tables below shows the differences between kalsa brics with clay bricks
and cement bricks.

No

Properties

Kalsa Bricks

Clay Bricks

Cement Brics

Compressive Stress
Drying Shrinkage
Water Absorption
Fire Resistance

10 - 25 MN/M
0.01%
10 15%
Half Brick:

10 - 12 MN/M
0.04%
30 35%
Case To Case

7 - 10 MN/M
0.05%
40 45%
Case To Case

4hours
Excellent
Excellent
Consistent With

Good
Good
Inconsistent

Poor
Poor
Inconsistent

Parallel Faces

With Irregular

With Irregular

2.8 2.9Kg
SIRIM Licensed

Faces
2.5 3.0Kg
Case To Case

Faces
2.8 3.1Kg
Case To Case

1
2
3
4

2hours
Full Brick:
5
6
7

8
9

Heat Insulation
Sound Insulation
Sizes

Weight
Certificate

27

IKRAM Listed

Case To Case

Case To Case

Bomba

Case To Case

Case To Case

10

Cost effectiveness

Approved
Low breakages

High breakages

High breakages

11

After curing

(<1%)
Free from

(15% - 20%)
Contain

(20% - 30%)
Contain

soluble salt

impurities and

impurities and

No efflorescence

soluble salts.

soluble salts.

will occur after

Efflorescence

Efflorescence

paintworks or

will occur after

will occur after

any form of

paintworks.

paintworks

12

surface treatment
BS EN 771-2
MS 76

standard

MS 76

(BS 187)
BS 476 - 2
Table 3.1: bricks comparison
Source: KALSA bricks article

Projects Using Kalsa Calcium Silicate Bricks in Malaysia are as follows:-

i.

Selangor Turf Club

ii.

Wisma Time

iii.

Wisma Chinese Chamber

iv.

Kelab Golf Sultan Abdul Aziz Shah

v.

Hotel Istana

28

vi.

Science Center

vii.

KL Tower

viii.

Menara Public Bank

3.3.2

Fly Ash Bricks

In the United Kingdom fly ash has been used for over fifty years to make concrete
building blocks. They are widely used for the inner skin of cavity walls. They are
naturally more thermally insulating than blocks made with other aggregates.
Ash bricks have been used in house construction in Windhoek, Namibia since the 1970s.
There is, however, a problem with the bricks in that they tend to fail or produce unsightly
pop-outs. This happens when the bricks come into contact with moisture and a chemical
reaction occurs causing the bricks to expand.
In May 2007, Henry Liu, a retired 70-year old American civil engineer, had invented a
new, environmentally sound building brick composed of fly ash and water. Compressed
at 4,000 psi and cured for 24 hours in a 150 F (66 C) steam bath, then toughened with
an air entrainment agent, the bricks last for more than 100 freeze-thaw cycles. Owing to
the high concentration of calcium oxide in class C fly ash, the brick can be described as
"self-cementing". The manufacturing method is said to save energy, reduce mercury
pollution, and costs 20% less than traditional clay brick manufacturing. Liu intends to
license his technology to manufacturers in 2008. Bricks of fly ash can be made of two
types. One type of brick are made mixing it with about equal amount of soil and
29

proceeding through the ordinary process of making brick. This type of formation reduces
the use of fertile sand in making bricks.
Another type of brick can be made by mixing soil, plaster of paris and fly ash in a
definite proportion with water and allowing the mixture to dry. Because it does not need
to be heated in a furnace this technique reduces air pollution.

3.4

The Smart and Cool Homes System for Floor

Floor or slab spends largest cost on concrete. Thus, many inventions have been

made to reduce the usage of the concrete but without effecting the effectiveness and
strength of the floor.

3.4.1

Voided Biaxial Slab (Bubble Deck)

In the 1990s, a new system was invented, to reduce the usage of concrete. The so
called Bubble deck technology invented by Jorgen Breuning, locks ellipsoids
between the top and bottom reinforcement meshes, thereby creating a natural cell
structure, acting like a solid slab (www.wikipedia.com). For the first time a
voided biaxial slab is created with the same capabilities as a solid slab, but with
considerably less weight due to the elimination of superfluous concrete.

30

Photo 3.9: bubble deck during concreting process

This so-called ball slab floor system is a smart and efficient structure on the basis
of customized prefab floor elements. Savings in materials and complete reuse are
distinctive features for Smart and Cool Homes system. The plastic balls do not
stick to the concrete. Therefore, both the concrete and plastic are suitable for highquality reuse. Flexible arrangement of buildings is self-evident when using this
level floor system. Heating and cooling of buildings, in conjunction with savings
in energy, are possible thanks to the application of a customized ball slab floor
fitted with the necessary installation systems. Adding all this, the bubble deck slab
floor forms the ideal application in fine aesthetic works. In those cases where the
architects and the builder are seeking a straightforward solution for the design of
the superstructure, bubble deck offers the solution. The result: an efficient and
cost-effective construction offering maximum added value to the user.

31

Photo 3.10: the plastic balls used as the bubble deck

Bubble deck slabs are suitable for use in all building types, and are particularly
suited for open floor designs, such as commercial, educational and institutional
buildings. Experience has also shown the most cost effective application of the
technology is through semi-precast elements. The size of the elements should be
maximized to increase cost efficiency, however this is generally limited by local
transport restriction.

Photo 3.11: construction using bubble deck system for Stiefel Laboratories, Sligo, Ireland

32

Photo 3.12: construction using bubble deck system on progress for school building.
Many countries in the world today already implemented this system for their
countries building as this system has more advantages compared to the
conventional method. The advantages are:
i.

Save cost
The amount of materials - concrete, columns, rebar, transfer beams and
other materials is reduced by up to 50%: 1 kg recycled plastic replaces 100
kg concrete. Slabs are factory produced and shipped to site as required.
Transportation costs are substantially reduced. Shoring is considerably
reduced and bubble deck slabs replace expensive formwork. Prefabrication and easy installation result in faster construction time. Less
man-hours equals lower costs and overhead. Clients get a design they want
for a better price. Interior finishing is less costly. Life span of buildings is
greater. The potential saving of a building designed in bubble deck is 25%
of the structural cost. Bubble decks advanced technology eliminates nonstructural concrete. So it can provide up to fifty per cent longer spans
between columns with no beams.

33

Figure 3.5: A typical building structure with the Bubble Deck floor system
ii.

Design flexibility
Bubble deck allows for superior design flexibility - dramatic architectural
shapes, larger spans and overhangs. No drop beams or carrying walls and
fewer columns are required allowing for spacious and flexible interior
layouts. Interior layouts are easily altered throughout a bubble deck
building's lifetime. Bubble deck conforms to engineering designs and
building codes, has less weight and less seismic load.

iii.

Less energy consumption

Less energy consumption in production, transportation and construction.
Less emissions - exhaust gases and vapors during production, transport
and on-site; (CO2 and other emissions - reduced up to 50%). Less
material consumption - cement, aggregates, water, steel. Every bubble
deck component can be recycled.

3.4.2

U-boot

U-boot beton is a formwork made of recycled polypropylene, designed to create

lightened intermediate slabs and raft foundations in reinforced concrete. The use
of U-boot formworks permits to build specific mushroom slabs. The mushroom is
part of the slab thickness. The formwork remains dip into the concrete casting.
Thus a grid of orthogonal beams, superiorly and inferiorly closed by plane slabs
34

of different heights, is obtained without executing two distinct concrete casting.

All that implies are remarkable saving of concrete and reinforcement.

Photo 3.13: U-boot beton formwork

35

Photo 3.14: U-boot beton while concreting

U-boot permits to build big spans slabs or slabs supporting high loads without
beams. By using this U-boot system, draftsman can change the geometrical
parameters of the slab, in order to suit any kind of situation.
U-boot is used in all applications that require a plate structural solution, along
with concrete saving and therefore weight savings. In tower buildings, weight
saving at every floor reduces load on foundation. The fact of avoiding beams
being out of the slab thickness, enables the reduction of heights for each floor.
Therefore, a higher number of floors can be built. By using U-boot beton,it is
possible to build thick raft foundations with reduced quantity of concrete and
weight. U-boot is the ideal solution to create slabs of big spans and with high
bearing capacity. In case of difficult access to the building site or restricting, Uboot beton permits to build up the horizontal structures without using lifting and
movement devices, because of its stackability, and manageability.

36

Photo 3.15: result after using U-boot system. Fewer columns required
The advantages of using U-boot system (www.daliform.org):
i.

Light weight
It is light weight because it decreases of concrete and weight up to 40%. It
also can decrease deformation, load to carry by the foundation and so the
pillar section.

ii.

Flexible
It may absence of beams between pillars. It also can spans to 20 meter
maximum. No lifting and movement devices required.

iii.

Economic
This system needs less concrete incidence. So the contractor would not
have to spend money on the concrete. This system provides usable height
saving on each floors. It also provides savings on transport and easy
stocking since it is stackable

3.5

Constructing Concrete Ground Floor Slab by Using Conventional Method

37

The types of structural floor likely to be encountered in building construction are

(Colin, 1978):
i.
concrete ground floors
ii.
timber ground floors
iii.
concrete upper floor
iv. timber upper floor
But, in this report, it will discuss only about concrete ground floor slab, as referred to the
report title.
According to Colin (1978), concrete ground floor slab are often referred to as solid
ground floors. Ground floor slab is the bottom part of a building which receive all activity
from the occupant and other load whether dead load or live load. A solid concrete slab is
the perfect base for laying ceramic floor tiles, slate, stone, marble or terracotta in
kitchens, dining rooms and hallways as compared to suspended concrete slab.
The advantages of concrete ground floor slab are that it is a relative inexpensive form of
residential foundation, they are very stable when properly designed and constructed and
helps obstruct termites from entering the house. When properly constructed they offer
very few spaces in the foundation itself for termites to intrude in to the structure from
below. This assumes that all pipe penetrations are properly sealed with stainless steel
wool or adequate caulk to prevent their passage.
3.5.1

Functions of Conventional Concrete Ground Floor Slab

Floor slab always plays an important rule for a building. Base on Cuypers (1987), in his
book called Ilmu Bangunan. Ground floor slab is a base of a building which receives
any activity from the occupant and other loads such as dead load, live load and even wind
load. Concrete floor slab construction must guarantee safety and comfort of the occupant.
Thus, there are a few ground floor slab functions that must be implemented in a concrete
ground floor slab construction (Tan, 2000) by using conventional method which are:

38

i.

To receive any kind of load before the loads will be transfer to the building

ii.

structure.
To spread all loads received to a greater area, especially for ground floor slab and

iii.
iv.
v.
vi.

to stop ground water from entering the building.

To separate between spaces.
To absorb sound waves
To guarantee its stability and may avoid cracks.
To be able to stop water absorption and prevent dampness from entering the

vii.

building.
As a comfort aspect. Comfort aspects are including thermal comfort, smooth

viii.

without slippery and nice to see.

Easy to do maintenance. This shows the character of floor. Lesser maintenance it
need, the better.

3.5.2

Types of Concrete Ground Floor Slab

There are three types of ground floor slab. The type to choose to be implemented on site
is according to the ground characteristic. Below shows the three types of the ground floor
slab.
i. T-Shaped
A traditional foundation method to support a structure in an area where the ground
freezes. A footing is placed below the frost line and then the walls are added on
top. The footing is wider than the wall, providing extra support at the base of the
foundation. A T-shaped foundation is placed and allowed to cure; second, the
walls are constructed; and finally, the slab is poured between the walls.

39

Figure 4.1: T-shaped ground slab

ii. Slab-on-grade foundation

As the name suggests, a slab is a single layer of concrete, several inches thick.
The slab is poured thicker at the edges, to form an integral footing; reinforcing
rods strengthen the thickened edge. The slab normally rests on a bed of crushed
gravel to improve drainage. Casting a wire mesh in the concrete reduces the
chance of cracking. A slab on grade is suitable in areas where the ground doesn't
freeze, but it can also be adapted with insulation to prevent it from being affected
by the frost heaves.

Figure 4.2: slab-on-grade foundatio

40

iii. Frost Protected

This method only works with a heated structure. It relies on the use of two sheets
of rigid, polystyrene insulation, one on the outside of the foundation wall and the
other laid flat on a bed of gravel at the base of the wall, to prevent freezing, which
is a problem with slab-on grade foundations in areas with frost. The insulation
holds heat from the structure in the ground under the footings and prevents heat
loss from the edge of the slab. This heat keeps the ground temperature around the
footings above freezing.

Figure 4.3: frost protected slab

41

3.5.3

Layers of Conventional Concrete Ground Floor Slab

The construction of a solid ground floor can be considered under five headings: the
hardcore, blinding, damp-proof membrane, concrete bed or slab and reinforcement bar.

Figure 4.4: layers of ground floor slab

i.

Hardcore

42

According to wikipedia, hardcore is used as a sub base after building the

foundation wall to make up levels before casting the ground floor concrete slab.
The recommended is hard stone ballast or quarry waste that should not pass a
sieve of more than six inches when broken down. This shall be free of weeds,
roots, vegetable soil, clay, black cotton soil or other unsuitable materials. Broken
stones or brick cuttings can also be incorporate. The purpose of hardcore is to fill
in any small pockets that have formed during over site excavations, to provide a
firm base on which to place a concrete bed and help to spread any point loads
over a greater area. Hardcore is usually laid in 100-150mm layers to the required
depth, and it is important that each layer is well compacted, using a roller if
necessary, to prevent any unacceptable settlement beneath the solid floor (Roy
and Roger, 1973).
If the site is slopping, the hardcore thickness must be averaged, as in the case of
solid floors, if the concrete bed is horizontal (Collin, 1978)

Photo 3.16: quarry waste as hardcore

43

Photo 3.17: roller

ii.

Blinding

Roy and Roger (1973) say that blinding is used to even off the surface of hardcore
if e damp-proof membrane is to be placed under the concrete bed or a reinforced
concrete bed is specified. According to Tan Boon Tong (1990), blinding should be
well compact and well flattened. The purpose of blinding is mainly to avoid the
damp-proof membrane from being punctured by the hardcore. It also purposes to
provide a true surface from which the reinforcement can be positioned.
Blinding generally consists of (Roy and Roger, 1973):

a layer sand 25-50 mm thick or

a 50-75 mm layer of week concrete (1:12 mix usually suitable)

44

Photo 3.18: concrete blinding.

Source: www.google.com

Photo 3.19: sand blinding

Source: www.google.com

45

iii.

Damp-Proof Membrane

Part of building which is next to the ground shall have a damp-proof membrane as
to prevent the passage of moisture from the ground to the upper surface of the
floor. According to a webpage, damp proof membranes (DPM) can be installed
over or under the concrete slab (refer figure--), the advantage of installing under is
that the DPM will prevent any moisture reaching any re-enforcing steel in the slab
and it will also retain liquid in the concrete, slowing down the hardening process
and ultimately giving a stronger concrete slab floor. The damp proof membrane
should be joined with double-sided mastic strip, or butyl tape to create a
waterproof barrier, and then seal down the edges with jointing tape.

Photo 3.20: jointing tape

The damp proof membrane should normally be covered with a layer of soft sand
to act as a protection and to prevent damage when the concrete flooring or screed
is installed.
The position of a damp-proof membrane, whether above or below the concrete
bed, is a matter of individual choice. A membrane placed above the concrete bed
is the easiest method. A membrane placed below the concrete bed has two
46

advantages (Roy and Roger, 1973). First, it will keep the concrete bed dry and in
so doing will make the concrete bed a better thermal insulator. Second, during
construction, it will act as a separating layer preventing leakage of the cement into
the hardcore layer, which could result in a weak concrete mix.
iv.

Concrete Bed or Slab

Concrete bed or slab is made of 1:3:6 or 1:2:4 concrete mixes which is laid above
the bedding. Concrete bed could be unreinforced or reinforced concrete
depending on the needs. If unreinforced concrete is used, the thickness of the
concrete should be 100 150mm thick. But for the reinforced concrete, minimum
150mm thick of concrete is required. Before the concreting work starts, there are
a few concrete property test should be done in order to ensure the concrete that
will be used is a quality concrete.
There are many different procedures to test the properties of concrete. The two
most common tests are the slump test, applied to wet or fresh concrete, and the
compression test, applied to hardened concrete (Jack, 1976).
a. Slump test
Slump test is suitable for establishing uniformly of mixes in subsequent
batches or deliveries. It is not test for workability, but it can be used as a
guide. Mixes of the slump test can vary with regard to their cement
content and grade of aggregates.
The equipment used for the slump test are: an open-ended steel frustum of
a cone, a tamping rod and a ruler. The procedure: the cone is one quarter
filled with concrete and temped 25 times. A further three layers are
applied, each layer tampered as described. Surplus concrete is struck from
the surface, and the cone is raised immediately. The cone was then turned
47

upside down and placed next to the concrete. The tamping rod is placed on
the cone, the slump of the concrete is measured and recorded.
Typical slump (Roy and Roger, 1973)
Mass concrete/thick sections of reinforced concrete,

50mm.

Roads, hand tempered and general use,

100mm.

Thin sections of reinforced concrete,

150mm.

b. Compression test (Cube test)

Concrete test cubes are made from samples taken from site. Samples are
taken before and during the placing of concrete.
The equipments used for this test are: standard machine steel mould,
150mm x 150mm x 150mm for aggregate size up to 40mm or 100mm
cube moulds may be used for aggregates up to 20mm. Internal faces of the
mould are lightly oiled prior to receiving concrete, a 25mm square
tamping rod with 380mm long.
The procedure (Roy and Roger, 1973): concrete is placed in the mould in
50mm layers. Each layer is tampered 35 times for 150mm cubes or 25
times for 100mm cubes. Alternatively, the concrete may be compacted by
using vibrator. Surplus concrete is struck off. Samples remain in the mould
for 24 hours, covered with a damp sack or similar. After this time, the
samples are marked, removed from the mould and submersed in water at
temperature between 10 and 21C until required for testing. The cube
strength is the stress failure after 7 days. If the strength specification is not
achieved at 7 days, a further test is under taken at 28 days. If the
specification is not achieved at 28 days, specimen cores may be taken
from the placed concrete for laboratory analysis.
48

Typical 28 days characteristic crushing strengths (that below which not

more than 5% of the test result are allowed to fall) are graded 7.5, 10, 15,
20, 25, 30, 35, and 40 N/mm. As a guide, shear stress of the concrete is
taken approximately one-tenth of the stress under compression (Roy and
Roger, 1973).

Portland Cement Association says in their website that, curing has a strong
influence on the properties of hardened concrete such as durability, strength,
water tightness, abrasion resistance, volume stability, and resistance to freezing
and thawing and deicer salts. Exposed slab surfaces are especially sensitive to
curing. Surface strength development can be reduced significantly when curing is
defective.
Curing the concrete aids the chemical reaction called hydration. Most freshly
mixed concrete contains considerably more water than is required for complete
hydration of the cement; however, any appreciable loss of water by evaporation or
otherwise will delay or prevent hydration. If temperatures are favorable, hydration
is relatively rapid the first few days after concrete is placed; retaining water
during this period is important. Good curing means evaporation should be
prevented or reduced.
There are many types of curing process can be done. For example, by covering
the concrete using polyethylene sheets or wet gunny sack, by spraying liquid
membrane-forming compounds on the concrete slab surface and also by using
burlap.

49

Photo 3.21: covering concrete slab using polyethylene sheets

Photo 3.22: spraying the slab using liquid membrane-forming compounds

50

Photo 3.23: burlap or water sprinkler

v.

Reinforcement Bar or Welded Wire Reinforcement

Concrete is very strong when it is squeezed in compression but very weak when it
is being pulled apart in tension. A good rule of thumb is that it is about 10 times as
strong in compression as it is in direct tension. Thus, whenever there is a crack on
a ground floor slab, it is due to it having more tensile stress applied to it than its
tensile strength (Wayne, 2007). Using reinforcement bar is only an option for
ground floor slab. Steel reinforcing bars and welded wire reinforcement are very
strong in tension, have similar thermal expansion and contraction properties to
those of the concrete, and thus can handle high-tension stresses while the concrete
can take substantial compressive stresses.

51

CHAPTER 4

CONSTRUCTING CONCRETE GROUND FLOOR SLAB BY USING

USED TYRES (THE SMART AND COOL HOMES SYSTEM)

4.1

Introduction

Space U8 is a new Shop Unit Mall Office which situated at Bukit Jelutong, Shah
Alam. The project title is as follows:

CADANGAN MENDIRIKAN PUSAT PERNIAGAAN YANG MENGANDUNGI:v.

vi.
vii.
viii.

232 UNIT KEDAI PEJABAT STRATA;

1 UNIT KOMPLEKS PERNIAGAAN 4 TINGKAT
1 UNIT RUMAH SAMPAH
3 UNIT SUBSTESEN ELEKTRIK

DI NO.6 (LOT PT 33313), PERSIARAN PASAK BUMI, TAMAN BUKIT JELUTONG,

SEKSYEN U8, SHAH ALAM, SELANGOR UNTUK TETUAN MAINSTAY
DEVELOPMENT SDN. BHD.

52

Figure 4.1: site location

Photo 4.1: Space U8 model

53

This project is developed by Mainstay Development Sdn. Bhd. The main contractor is Sin
Seong Hin Sdn. Bhd. Space U8 was design by Aqidea Architect, as the project main
architect. The company which has to control on the structural, and mechanical and
electrical (M&E) work is KTA Tenaga Sdn Bhd.

The overall cost for this project is RM84 million. Located in Bukit Jelutong, the complex
spans 3.2ha and consists of 58 units of four-storey shops and offices as well as two
basement floors. A large 6,300sqm courtyard in the middle of the complex is the jewel of
the buildings crown and the main beneficiary of the Smart and Cool Homes technology.

Mainstay Development Sdn Bhd decided to make its new Shop Unit Mall Office
development complex in Shah Alam as environmentally friendly as possible. One of the
measures taken towards that goal is an unusual one incorporating almost 220,000 used
rubber tyres into the foundation of the building.

The board has decided to implement the Smart And Cool Homes (SCH) system in the
Board meeting in February 2009. The implementation of the system was intended to
bring down the temperature of the courtyard and the of Space U8 development by few
degrees. The implementation of the SCH is the first for a commercial development in
Selangor. Previously, the SCH has been utilized for development of residential units.

54

4.2

The Tyre System (Smart and Cool Home)

Space U8 will be the first ever commercial building to utilize the revolutionary
Smart and Cool Homes technology invented and patented by Lincoln Lee which using
used tyre as the ground slab. The system uses tyres to create a heat sink that drains the
heat from walls built with autoclaved aerated concrete bricks, thus making the building
interior cooler and minimizing air-conditioning needs. With this system, the temperature
can be lowered by 2C to 3C. So there might not be a need for air-conditioning. It wont
be cold but it will be cool and comfortable, with proper wind flow taken into account. Mr.
Lee said the technology saved money that would otherwise be spent on cooling the
building. Base on a website, the biggest bill a building management has to pay every
month is usually the one for air-conditioning. But after using the smart and cool system,
the management can save 50%-60% of the electricity used for a building say Mr. Lee.

Base on a web site, fans do not remove heat. They merely help with the evaporation
process. When human sweat, the moving air created by the fan increases the rate of
evaporation, making one feels cooler. The temperature of the air remains the same. The
fan with moving motor actually contributes heat to the air space because motors generate
heat.

So, this is how the tyre works. First, when heat from outside enters the wall, air bubbles
in the aerated concrete blocks (AEC) slow down the transition of heat through the walls.
Then, the heat sinks created by the tyres absorb the heat before it escape into the building.
So, the interior building remains cool. The interior building temperature reading can be
reduce up to 5c as compared to other building which using conventional method. See
figure at next page:

55

Figure 4.2: the tyre system works.

4.3

Functions of Using Used Tyres as The Ground Floor Slab For Smart And
Cool Homes System

Other function of constructing concrete ground floor slab by using used tyres is as
same as conventional method as per discussed in chapter 4. However, by using the Smart
and Cool Homes system, it has extra function and gift more benefit to the occupant. In
short, functions of using used tyres as the ground floor slab or in other words, using the
smart and cool home system are as follows:i.

The tyres placed under the ground slab works as heat sink to remove the heat

ii.

from the building.

Upper floor slab is less massive than normal RC slab, and stored less heat. It is

iii.

also corrugated, giving it more surface area to release heat faster if stored.
Heat penetrating the building is prevented from travelling into the building (by the
insulated blocks) and conducted by the concrete on the wall surface to the ground.

56

iv.

More superior construction quality and lower cost as compared to conventional

v.

building of similar acoustic, thermal comfort level and energy efficiency.

Achievable average indoor air temperature range of 25C - 28C (which
represents

the

comfortable

temperature

range

of

most

Malaysian).

Reduced heat stress and improved ventilation will create a conducive environment
for longer occupancy and thereby reduce incidences of child delinquencies
vi.

outside the home.

As the house is thermally comfortable, less active cooling is required. Thus saving

vii.

in electrical usage of 30 - 40% can be achieved.

As the home is energy efficient, it is readily adaptable to grid-connected PV

viii.

(Photovoltaic) to generate cash returns.

Reduced use of air-conditioners leads to reduction of electrical power
consumption, and this lessens fuel burning and therefore also carbon emission.
Reduced use of air-conditioners lowers emission of CFC gases and minimal

ix.

timber formwork will help to reduce global warming.

Most of the work in our system is dry construction, making the site clean and
neat. Little timber formwork is used, therefore minimizing the need for setting up

x.
xi.

and dismantling of wooden formwork, as well as burning of wooden formwork.

Long lasting materials and will require low maintenance.
The ground floor slab is waterproof, making it more flexible to use various

xii.

materials for the ground floor, such as timber strips.

As the ground floor slab is waterproof, it becomes termite proof as well, making it
unnecessary to use toxic materials to termite-proof the floor slab. And it stays
termite proof forever, unlike chemical treatment which can last for generally two
years only.

4.4

Temperature Reading on Site Space U8

57

Some temperature measurement had done on site. It is due to response to

Mainstay Development quarries to clarify on the coolness of the floor slab with tyres.
Since the introduction of the SCH system to the client side explained that it must be used
completely and holistically to achieve the optimal results and receiving the features and
benefits of the system. In the case of thermal comfort, test is usually conducted after the
completion of the building and not during construction phase.

However, as there is a need to see whether using the tyres in the foundation really is
cooler than normal concrete slab, temperature measurement was done after the
completion of the mock-up unit basement 1 (without aerated blocks). The temperature
measurement was conducted on 25th May 2009. The results are as bellow.

Chart 4.1: surface temperature measurement at Space U8

From the chart above, it is confirmed that the temperature at the basement (tyre floor
slab) is much cooler than other area on site. But, the client wants to know is it the
58

coolness resulted at the basement is due to the tyres system. So another test was done to
compare the result of basement temperature. The client, and so the other parties involved,
had went to Mid Valley Megamall to take temperature sample. For information, Mid
Valley Megamall had used conventional method for the basement. The result is as
follows:
Location

Outside temperature, C

Basement temperature, C

Space U8

42

30

Mid Valley Megamall

41

36

Table 4.1: temperature reading at two different locations

Source: temperature test report, Space U8, Bukit Jelutong

Thus, we can conclude that, this tyre system can be use successfully as a cooling system.

4.5

Method of Construction

The process of constructing this type of floor plays the most important rule since
this system is a new system implemented for a commercial building. Many precautions
have to take during the construction process. There are two methods to construct ground
floor slab by using used tyres.
i.

Monolithic concreting
Monolithic concreting means that the contractor has to rearrange the tyres first
then only the beams. The beams will be concreted together during the process of
concreting the slab. In other word, the tyre cage will be acting as the beams
formwork.

ii.

Non-monolithic concreting
Non-monolithic concreting means that the contractor has to construct the beam
first by using formwork. After the beam is ready, the tyres are filled.
59

But, for Space U8 site, all parties agreed to use monolithic concreting method. Thus
below is the process of constructing.

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y
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e

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r
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s

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i
e d
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t

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Chart 4.2: process of constructing ground floor slab by using used tyres.

i.

Soil investigation and designing the foundation

A detailed soil investigation has take precedence by a qualified person of
all foundation design works. Foundation design is prepared by a qualified
engineer. It is recommended that the pile cap to be constructed at level
below the bottom tyres. The tyres was then sit on the pile caps and the
ground beams are to be designed to the engineers requirements.

60

In the event where a better heat sink is desired for a higher thermal
comfort, additional excavation is done for the placement of additional
layers of tyres. It is strongly recommended that the layers of tyres to be
not more than 4 layers in height. All the backfilled material is compacted
well.

ii.

Preparing the base

The ground is cut to the required level to minimize the thickness of the
sand bedding required for fixing the level of the ground beam. Then, the
soil is compacted to engineers specifications. It has to assure the top level
of the pile cap and pad footing is as same as ground beam level.

Photo 4.2: soil compaction

iii.

Setting the building lines

The building lines are set according to the construction drawing. 1m high
timber peg is used to mark the building lines. The raise-up ranges from
200mm to 900mm depending on the number of tyre layers.

61

Photo 4.3: building line setting up

iv.

Preparing the perimeter formwork

Either timber or metal formwork can be used as the perimeter formwork.
But as for this project, they used plastic formwork as the perimeter
formwork. Plastic formwork is more workable and can be used as many
times as it can be. The height of the perimeter formwork ranges from
200mm to 900mm depending on the number of tyres layer. A sand bed
with thickness of 50mm to 75mm is prepared within the enclosed area of
the formwork. A stretch of 1m to 2m uncovered is left to allow the tyres to
be rolled into the enclosed area. All the underground piping ducting or
services for electrical, portable water, sanitary, sewerage etc is installed by
this time.

62

Photo 4.4: compacted blinding

v.

Arranging the tyres

The location of ground beam was set up by using string. Next, the tyre is
rolled into the formwork area. The dotted lines shown in figure below,
indicates the ground beams. The drawing is checked to determine the level
of each area of the structure. At drops in area specified in the construction
drawing for example, kitchen and bathroom, the thickness of the sand
bedding is reduced.
Since the tyres came in various size, and height, the thickness of sand
bedding is added or reduced to adjust the height of the tyres to achieve the
uniformity in height arrangement. A clever selection of tyres is applied to
achieve a good tyre arrangement.
The sand is filled into the perimeter tyres of each tyre group to create
lance in order to minimize the movement of tyres during concrete
casting. The horizontality and the verticality of the tyres are checked.

63

Photo 4.5: rearranging tyres

Checking is done to make sure that the top tyre level does not exceed the
slab level of the structure. For single layer tyres, minor height adjustment
of 5mm is required during concrete pouring. For two layer tyres, minor
height adjustment of 10mm is required during concrete pouring. For three
layer tyres, minor height adjustment of 20mm is required during concrete
pouring. For four layer tyres, minor height adjustment of 30mm is
required during concrete pouring. The height of tyres will reduce when the
wet concrete induces self weight of them. But, as for this site, three layers
of tyres is implemented.

Photo 4.6: three layers of tyre

64

vi.

Caging the tyres

Wire mesh 50mm x 50mm is put on the top of the tyres but without
crossing the ground beam area. With a minimum overlapping of 100mm,
the wire mesh was then is tied with wire on the overlapping areas.

Photo 4.7: caging the tyres

As for the perimeter ground beam, an L shape is followed and bended at
the tyre area with an overlapping of 100mm. It is tied very firmly with
wire. As for the external beam, an U shape is formed and slot it into the
internal beam area, with a bend on both sides of 100mm over lapping. One
must make sure that the tyres are caged up firmly and tightly. At the
centre, 2 numbers of Y12 forming a cross of 800mm in length each to be
placed on the top of the 50mm x 50mm. this only happen to big boxes.

65

Photo 4.8: tyres caged

vii.

Forming the ground beam using poly propylene sheet (PP sheet)
The PP sheet is measured, cut and folded it to the size of ground beam.
Size of the PP sheet is 2mm thick only for single and two layer tyres. For
three and four layers tyre, a 4mm thick PP sheet is used.
The folded PP sheet is placed onto the ground beam, on the top of the
50mm wire mesh. If the PP sheet is too short, overlapping of 100mm is
required. Same as for the top of PP sheet of the corners bent over with a
100mm and is tied with wire against the 50mm formwork. By this stage,
one can see the ground beam formwork completed. For the overlapping,
the PP sheet is bent at join each other together, a 75mm thick masking tape
is sealed at the joint.

viii.

Covering the wire mesh using polyethylene sheet (PE sheet)

For areas that are not covered with PP sheets, a layer of PE sheet
(approximately 0.5mm to 1.0mm thick) is covering all the remaining area
that is exposed with tyres and 50mm x 50mm wire mesh. Then, the PE
sheet is laid on the tyres and if the PE sheet is too small, the other layer
66

must have an overlapping with a minimum of 100mm and sealed properly

with a 75mm thick masculine tape. As for the corner of the beam, the
overlapping of 100mm over the PE sheet is required and uses the
masculine tape to seal up all the joints which must be done properly.

ix.

Reinforcing the formwork

The ground beam re-enforcement is placed or to the respective area with a
10mm spacer at the bottom. For every box, a Y12 is placed at each corner
of the box as shown in the diagram, bent in a U shape of a total length of
1600mm. then, wire mesh is placed on top of the PP sheet in accordance to
the engineers requirement and spacer of 10mm. Next, the concrete level
and the concrete thickness is marked in accordance to the engineers
requirements.

x.

Preparing the drops

Formwork for the drops of the kitchen, bathroom, car porch and even split
level that are required for the ground beam was set up. Afterwards, all the
necessary plumbing pipes and electrical pipes which are required in the
design are placed to avoid any hacking of the ground floor slab in the
future. Very important: this is water resistant and termite proof monolithic
box raft system and any hacking on the slab will not help it to achieve its
purposes.

xi.

Casting concrete
First of all, all rubbish and debris is cleared at the ground beam or on top
of the tyres box foundation. Then, concrete is poured slowly onto the
perimeter beam first only to half the beam depth, after that to the internal
ground beam of half beam depth. Concrete is then poured onto the
67

perimeter beam to the same level of the tyre box. The concrete is vibrated
to avoid honeycomb. The concrete is poured on the slab to the required
thickness and is flattened along the way.

Figure 4.9: concreting process

When the water subsides and the concrete hardens overtime, check
whether there are hairline cracks. If there are hairline cracks, mix bed
adhesive with fine sand and plaster over the respective hair line cracks.

xii.

Removing the perimeter formwork

The perimeter formwork is removed gently on the next day. Honeycomb is
checked. After that, block work is started.

CHAPTER 5

68

PROBLEM STATEMENT AND SOLUTION

5.1

Introduction

Building constructions nowadays are facing many problems and obstacle. None of
project is facing with zero problems. Same goes to the Space U8 site. Many problems
occurs during construction.

5.2

Problems and Solution

For this report problem statement, it will focus on the problems occur before,
during and after the process of constructing the ground floor slab by using tyres at the
mock-up unit on Space U8 site.

5.2.1

Sagging Of Slab

In the letter wrote by the main contractor, stated that there are concrete sagging
occurs at the mock-up unit. This problem causing wastage of concrete to up to
30%, although the system inventor mentioned that by using this system, the client
can save cost on concrete. The sagging of slab is due to the tyre characteristic;
elastic and springy. So, when the tyres are imposed by the heavy weight concrete,
it may cause the tyre to settle down. Thus more concrete needed to pore to the
required level. The settlement occurs especially at the middle portion within the
two beams.

69

After discussion and study has been made by Lucas Sdn. Bhd., they have came
out with the solutions to prevent concrete sagging on the other unit at the Space
U8 site. The solutions are by making sand column and by increasing the heights
of the tyre.
Sand column is made of sand which is infill inside the tyres. This sand column
will act like a weak column to prevent the tyre settlement. An extra thickness of
sand blinding is needed to increase the level of tyre. Therefore, an extra cost
should be provided.

5.2.2

Insufficient Trained Labors

Since the Space U8 project is a 8 hector commercial building project, w ell

trained labor is found out insufficient on site. This tyre system is still a new
system in the world, thus, well trained labors should be provided by the systems
inventor company. Well trained laborers should be provided because it is not that
easy to rearrange the tyres since the tyres came in many sizes. The inventor only
provides two numbers of well trained labors, and they also not provide supervisor
to supervise work on site.
Lucas Sdn. Bhd. should provide more skilled laborers since this project is a huge
project. Not just to provide, but to decrease the salary that the main contractor has
to pay. Currently, the main contractor has to pay RM200 per day for a labor.
Maybe, they should decrease to RM150 per day. As for this site, atleast 5 numbers
of well trained labors should be provided. Another important thing is that, Lucas
Sdn Bhd also should provide a supervisor.

5.3

Suggestion

70

There are other methods to let the interior building remains cool which are by:
i.

ii.

iii.

Keeping out direct sunshine and heat

a. using large overhangs to protect internal spaces from solar radiation
b. ensuring that east and west elevations have few or no windows
c. admitting low sun, and that walls on these elevations are reflective and
well insulated
d. using low thermal mass materials to minimize heat storage
e. using shading devices to minimize solar gain.
Maximizing natural ventilation
a. north and south walls have large openings for ventilation
b. double-banking of rooms is avoided, if possible
c. shops are arranged to aid cross-ventilation
d. plans a open and free spaces between buildings
e. large volumetric ventilation is provided to remove internal heat
f. spacing of buildings optimizes access to breezes
Use orientation to best effect and breeze orientation should always be resolved to
control sun, with the design of both building and landscaping modified to deflect

iv.

available winds.
Roofs should be pitched to facilitate water drainage.

Figure 5.1: Stack effect

71

CHAPTER 6

CONCLUSION

Finally, we can conclude that, constructing concrete ground floor slab by using used tyre
(Smart And Cool Home System) will give a better impact to our environment. It is best to
be implemented for residential building. But for a commercial building, this system is
quite not suitable. An extra effort and research should be carried out so that this sytem
can be implemented to all types of building.
Smart and cool homes system should be implemented as a passive means to achieve
comfort as the nature of Malaysian climate necessitates mechanical ventilated or partial

72

air-conditioning interiors (on hot days). However, poor design and indiscriminate use of
air-conditioning have resulted in huge increases in energy use. So, passive and low
energy design strategies are better solutions for a sustainable future.
Thus energy efficient design should be directed towards reducing energy demands,
through:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.

natural and fan assisted ventilation,

correct opening schedules,
higher set-point temperatures (if air-conditioning is being used),
proper orientation and siting,
reduction of solar gain (i.e., shading devices),
thermally efficient construction (i.e., insulation)
low energy equipment and plant and
improved use of daylight.

Finally, trees that surround a house could also contribute to natural cooling of the house
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fertilizer on nutrient runoff from various vegetable roof system, United States, John
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Carter, T. (2006, May 6). A life-cycle cost-benefit analysis of extensive vegetated roof
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APPENDIX

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76