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SMART represents one of the latest attempts at computer integrated construction (CIC) that claims to reduce by 30% the number of man-hours required to complete a multi-storey office building. System set-up takes about six weeks, after which the building's top floor and roof are erected on top of four jacking towers: the effect is to resemble a top-hat. The jacking towers are used to push up the 1,323 ton top floor assembly - the main work platform - as well as lifting their own bases from floor to floor in a cycle time of around two and a half hours. The heart of the system is composed of lifting mechanisms and automatic conveying equipment which is installed on the work platform. This later becomes the roof of the building. Overhead gantry cranes are connected to the underside of the roof structure in a way that resembles a factory production facility. Trolley hoists are used to lift and position components which are introduced at ground level.
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Jacking post
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Gantry hoist
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Floor panel laying
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Roof top control room
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Photographs: courtesy of Shimizu Corporation
The whole process is computer-controlled, though workers are still involved in overseeing operations at least for the time being. Simplified connections between components facilitate rapid erection times: self-centering column connections require only fine-tuning with a torque wrench and a laser-guided gauge. A clamp-on welding robot - one of a few task-specific devices - is used afterwards to effect the final mating of the column ends. Floors emerge from under the top-hat pre-clad - again from the inside - allowing work in fitting out to begin immediately. Weather is excluded from the job-site by a mesh fabric hung around the work area. Racks of pre-assembled pipework are a further example of an entire approach to rationalising design and production, the aim of which is to drive down the man-hours required for production. In a country where there is a shortage of skilled construction workers, any innovation that brings a significant reduction in manpower is more than welcome.
SMART automates a range of production processes including:
- erection and welding of steel frames
- placement of precast concrete floor planks
- exterior and interior wall panels
- installation of various prefabricated units.
Inevitably, with the first run of anything, costs are higher than normal: it would be unusual if it were not so. However, further improvements to the system will enable it to have wider application and, hence, lower costs because of economies of scale and familiarity with the technology. Likewise, lower cost will make the system more attractive: it is, potentially, a winning formula.
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