CHAPTER 3

METHODOLOGY

3.1 GENERAL

In this chapter, all the methods validated for this study are presented in details. This research involved
the study of cold-formed steel as building material in residential building with respect to time and cost.
One cold-formed steel framed house was designed. The design was based on the dimension and design
of local residential requirements.

Comparison analysis was performed between cold-formed steel and one type of traditional construction
method with respect to time and cost. The method shown for the study was reinforced concrete as in
Sarawak, even Malaysia construction market is still primary reinforced concrete dominated. The
projection of construction cost also was analysed.

3.2 SOURCES OF INFORMATION

Before the study started, a lot of information needs to be collected. This information is very importanr in
deciding the method to be used for the study. The following paragraphs describe the sources whereby
relevant information were collected.

3.2.1 BACKGROUND INFORMATION

Firstly, some background information regarding cold-formed steel construction were collected in order
to understand this construction method and material clearer. This helps to distinguish the advantages,
disadvantages, problems faced, usage, and market comments on cold-framed steel construction as
compared with reinforced concrete construction. Below are some of the sources where information
were collected.

(ii) Center for Academic and Information Service (CAIS) in UNIMAS, Sarawak State Library and JKR Library

Through these organisations, information and designs of the cold-formed steel structures and reinforced
concrete structures can be found. Books, journals, magazine and reports are good reference sources.

(iii) Internet

Via the Internet, the information, reports and researches related to this topic can be searched. Many
important, useful and updated researchers are published online. The related researchers that have been
done for this topic can be used for cold-formed steel also can be found. The usage and new technology
of both cold-formed steel and reinforced concrete construction in other countries can be a good
reference for this research.

3.2.2 INTERVIEW

At the same time, interviews were conducted with experienced consulting engineers, contractor
engineers, cold-formed steel suppliers, architects and the developers. These are the people who hand
on the building materials and familiar with the materials. They have practical and use of the materials
experiences. The interviews provided relevant information on the market. The usage and the reaction of
the market were known. It provided a clearer guide for what and how to compare these two
construction methods. The interviews was basically divided into three main sections.
 In the first section, the extent of usages and impression of the respondents in cold-formed steel
were gathered. Through the interviews, the respondents shared the usage of CFS in building
construction in details. This gave a clearer pictures for the research about the common use of CFS in
Malaysia. Besides, interviews also helped to reveal what was the reason for using this construction
method and material. In this section, the respondents also shared the impressions of CFS in building
construction without comparing with other building materials.

The second section was for those who had not used CFS in construction before. This section focused on
the reasons and obstacles that stopped them from using this construction method and material. In the
last section, opinions gathered from respondents regarding the comparison between CFS to other
construction methods and materials. The respondents shared their preferences of construction method
and material and stating resource of preferences. They also gave their opinions about the suitability of
CFS in Malaysian construction industry.

3.3 DATA COLLECTION AND ANALYSIS

After reviewing the information and the local market reaction to cold-formed steel construction, the
construction materials were analysed to reveal their usage, comments, suitability and potential in
Malaysian building construction industry. This analysis helped to produce a more accurate comparative
result between cold-formed steel (CFS) with reinforced concrete (RC) in construction. The analysis was
carried out as described in the following paragraphs.

3.3.1 CASE STUDY

This case study used similar existing projects as a guideline for this study. The projects were local
residential construction projects.

3.3.1.1 Cold-Formed Steel Project

A house extension and renovation for roofing of an existing detached house project (using cold-formed
steel) was observed. This project was a pilot project in Kuching and gave a better understanding of steel
framed structure. Many observations, data collection and studies were conducted. Site visits were
conducted in order to observe the whole construction period including the transport of the steel
members, installation of the steel members and site condition. Besides, many important data were
recorded during the visit included the followings:

(a) Collection of labour hours

Before gathering labour hours, the works breakdown analysis needs to be carried out. The Work
Breakdown Structure (WBS) is the most useful tool to specify the project activities. With the
identifiable and manageable acticities or task, the labour hours for every day can be collected on
site. The labour headcount on site were also conducted.
(b) Daily schedule
Time scheduling was done by the contractor. The sequence and time needed for every task was
provided. This gave the total time needed for the project. Based on the observation, time
planning done for the project would be determined. Time estimation could be done more
accurately in accordance to local condition.
3.3.1.2 Reinforced Concrete Project

Some existing housing development projects of reinforced concrete house would be retrieved from the
Sarawak Housing Development Corporation. One of the projects would be used for study. The
information needed for comparison can be collected. This information included:

(a) Time schedule for the projects;

(b) Work breakdown structure for the projects;
(c) Drawing for the houses;
(d) Quantity of materials used for the projects;
(e) Number of labour and machinery used for the projects; and
(f) Quality of the houses (how to measure and comments from the clients/owners)

3.3.2 COLD-FORMED STEEL FRAMING DESIGN

Based on the sizes and designs of the reinforced concrete project, cold-formed steel framed house
would be designed. The design was accomplished using engineering software. The architecture features
and the materials used were not be exactly the same, but the dimensions and space allocation were be
the same. A detailed engineering drawing was produced. Study on the drawings would be done. This
helped to do the material take-off. Besides, some of the materials used in this project such as wall
cladding and floor were also decided in order to do the material take-off. The decision was made with
reference to past projects and opinion from architects and cold-formed steel suppliers.

From the drawings, the amount of materials consumed were determined. The materials were
determined. The materials were divided into different types and quantity. Materials needed were
calculated according to the engineering drawings. Wastage was considered for the projects. The total
materials needed for the project were determined and thus material cost projection for the project.

3.3.3 ASSUMPTIONS

As mentioned, cold-formed steel framed house was designed and not built in reality. So some
assumptions had to be made in order to obtain more accurate and viable result. Besides, both projects
needed to have some assumption so that they were comparable such as some number of plant and
machinery used and some working days. The followings are some of the assumptions made in this
research.

3.3.3.1. TIME ASSUMPTION

The number of working days for building construction in Sarawak is six days per week and eight hours
per day. The non-productive period for building construction is Sunday and public holiday set by
Sarawak Government. Both projects were assumed to start at the same time, i.e, 1st of January 2005.
The entire public holidays that would affect the construction period for year 2005 and 2006 are as
follows:

1st January 2005 - New Year’s Day

21st January 2005 - Hari Raya Haji

9th and 10th February 2005 - Chinese New Year

10th February 2005 - Awal Muharram

1st May 2005 - Labour Day (Replacement on the next day)

1st and 2nd June 2005 - Hari Raya Puasa

31st August 2005 - National Day

3rd and 4th November 2005 - Hari Raya Puasa

25th December 2005 - Christmas Day (Replacement on the next day)

1st January 2006 - New Year’s Day (Replacement on the next day)

10th January 2006 - Hari Raya Haji

29th and 30th January 2006 - Chinese New Year (Replacement on 31st January)

31st January 2006 - Awal Muharram

1st May 2006 - Labour Day

1st and 2nd June 2006 - Hari Gawai

31st August 2006 - National Day

24th and 25th October 2006 - Hari Raya Puasa

25th December 2006 - Christmas Day

1st January 2007 - New Year’s Day

18th and 19th February 2007 - Chinese New Year (Replacement on 20th February)

1st May 2007 - Labour Day

1st and 2nd June 2007 - Hari Gawai

31st August 2007 - National Day

For the purpose of comparing with cold-formed steel project, the time duration for the reinforced
concrete construction was estimated with reference to a real life project. It was because both projects
required the same labours supply in order to compare the construction duration. The cold-formed steel
project was a non-existing project and the time estimation was based on the experience of the
contractor and projection from a pilot project.

3.3.3.2 Cost Assumption

All costs for the projects were the recent market price rates in Sarawak obtained before 31st March
2006. The market price rates were obtained from the material suppliers, quantity surveyors,
experienced contractors and consultant engineers. Even though the actual cost for the existing
reinforced concrete project was available, the latest price was used for the comparison. The actual cost
for the project was used as reference.
 (a) Material Cost

Table 3.1 outlines a lot of major materials pricing schedule. The prices were based on the recent
rates in Sarawak which were obtained from material suppliers and contractors.

Table 3.1 Material Pricing Schedule

Ref. Item Price

1.0 Pile (150mm x 150mm x 6m) RM 21 per meter
2.0 Concrete
i. Grade 25 RM 210 per m2
ii. Grade 15 RM 100 per m3
3.0 Reinforcement Steel Bar
i. High Tensile Deformed Rod Reinforcement
Y10 RM 2.8 per kg
Y23 RM 2.8 per kg
Y16 RM 2.8 per kg
Y20 RM 2.8 per kg
ii. Mild Steel Rod Reinforcement
R6 RM 2.8 per kg
R8 RM 2.8 per kg
4.0 Formwork (including hardwood and plywood) RM 28 per m
5.0 Wire Mesh A7 (BRC A7) to MS 145:200) c/w Mill Certificate RM 8 per m2
6.0 Cold-Formed Steel Members
i. Roof RM 55 per m2
ii. Floor RM105 per m2
iii. Wall RM 20 per m2
7.0 Bondek (1.0mm thk) RM 95 per m2
8.0 Concrete Hollow Block (140mm thk) RM 1.10 per piece
(75mm thk) RM 0.80 per piece
9.0 Profile Steel Sheet (Zinclume) as external wall cladding – with RM 40 per m2
colours
10.0 Cement Board (Gypsum Board as internal wall cladding including RM 35 per m2
installation fee)

Cost assumption for other minor materials and wastage are as follows:

1. 5% of the total reinforced concrete or cold-formed steel material cost was considered as minor
tools used during construction such as:
Reinforced Concrete: saws, hammers, tape measures and others.
Cold-Formed Steel: saws, hammers, drywall screw guns, tape measures and others.
2. 5% of the total reinforced concrete material cost was considered as the minor materials used
during construction such as: nails, form ties, form liners and others.
3. 5% of the total reinforced concrete material cost was considered as construction wastage.
4. No wastage cost was considered for cold-formed steel construction because wastage had
already been considered in material cost.
5. 2% of the total reinforced concrete structure construction cost was considered as design fees.
(b) Labour Cost

The wages for the site supervisor was paid on monthly basis and the workers on site were paid on
daily basis. For the cold-formed steel construction, the wages of the workers during members’
fabrication were included in the material cost and the wages for the steel framers and cladding
installer were included in the installation cost. The workers were the supervisor, carpenter, cement
mason, rebar benders, bricklayers and other general workers.

For the reinforced concrete construction, cement mason, rebar benders, carpenters, bricklayers,
supervisor and other general workers were required. Table 3.2 shows the labour wage rates
schedule obtained from experienced contractors.

Table 3.2 Labour Wage Rates Schedule

Ref. Post Wage Rate (RM)

1.0 Site Supervisor 1800 per month/ 60 per day
2.0 Carpenter 35 per day
3.0 Bricklayer 25 per day
4.0 Cement Mason 25 per day
5.0 Bar Bender 25 per day
6.0 General Worker 25 per day

(e) Plant and Equipment Costs

Major tools and machineries required for these projects included a lorry, drop hammer pile driver,
JVC excavator, crane and concrete pumping machine. All these machineries were considered to be
rented for cost comparison purpose. Table 3.3 shows the rental rate for the machineries.

Table 3.3 Machinery Rental Rate Schedule

Ref. Item Rental Rate

1.0 Lorry RM 30 per hour
2.0 Deep Hammer Pile Driver RM 5 per meter
3.0 JVC (Excavator) RM 60 per hour or RM5000
per month
4.0 Craned RM 250 per day
5.0 Concrete Pumping Machine RM 300 (sub-contract)

3.3.3.3 Design Assumptions

(a) Cold-Formed Steel

The design of this cold-formed steel structure was carried out by EcoSteel Sdn Bhd with “Multi
Frame 3D“ software according to AS/NZS 4600. It offers automatic factoring of bad cases, automatic
inclusion of self-weight and a range of commands to automate the generation of regular geometry.
The design ultimate load with safety factor 1.2DL + 1.5LL is used, whereby DL is dead load and LL is
live load. Wind load needs to be determined at the site. For the reason that this was not an existing
project and had no real site, the wind load was assumed according to the experience of the
engineer. This assumption was good enough for strong wind in Sarawak. Detailed designs are
attached in Appendix C.

For Roofing

Loading:

Dead Load = 0.15kPa

Live Load = 0.25kPa

Ceiling Load = 0.25kPa

Wind Load = 0.486kPa

The dead load is including:

i. Truss Self Weight

ii. Insulation
iii. Metal Roofing Sheet
iv. Purlin/Bottom Self Weight

Spacing = 1.850 m

~ 1.900 m

Load acting on the Roof Truss:

Dead Load = 0.15 x 1.9 = 0.285 kN/m

Live Load = 0.25 x 1.9 = 0.475 kN/m

Ceiling Load = 0.25 x 1.9 = 0.475 kN/m

Wind Load = 0.486 x 1.9 = 0.930 kN/m

For first floor of the structures, bondek II (composite slab) was used. The design was in accordance
to design manual of BHP Steel Building. The followings are some of the weights of construction
materials which were used for this structure. Detailed designs are attached in Appendix D.

Concrete - 2400kg/m3

Bondek - Ay x 7850 x 9.81/1000

Where Ay is the cross-sectional area of bare metal of profiled sheet

within width of slab

(c) Reinforced Concrete

For this project, the structure was designed in accordance to Ultimate Limit State (ULS). The
maximum design ultimate load with safety factor 1.4Gk + 1.6Qk was used, where Gk was dead load
and Qk was imposed load of the structure. No wind load is considered for this structure. The
followings are some of the weights of construction materials which were used for this structure.
Reinforced Concrete - 2400kg/m3

Solid Mild Steel - 7650 kg/m3

3.3.3.4 Other Assumptions

There are other assumptions that were considered for comparison among different construction
methods.

(a) Daily Labour Working Schedule

The daily labour working schedule is important to estimate the time and cost. Appendix E shows the
schedule and description of work. All the works and labour allocations are listed in Appendix E and
the tables shows the monthly form whereby the labour cost was recorded monthly.

Using BC 10 units as an example, 10 general workers were arranged for site clearing and setting up
grid lines for 4 days. The number was not consistent and it would change in accordance to the needs
on site. As an example, the numbers of general workers would decreases to 5 for pile driving. This
was because there was only one (1) drop hammer pile driver on site and extra workers would not be
required. Sometimes, two (2) parallel works were arranged such as the bar bending work, starting a
bit later than the formwork. This is a normal practice on site.

Public holidays and Sundays are non-working days. So labour was not allocated for these days. For
waiting days during the hardening of the concrete, other works were arranged. So, there was no
wastage of time. The total labour cost for the project was recorded in a table form. This schedule
table not only gave a clear view about the labours needed every day during the construction, it also
helped the contractor prepare enough labour before the works began. It was a good guide for
labour control and also helped keep the progress on schedule.

(b) Plant and Machinery Rental Duration

The estimation for the rental duration is important for plant and machinery costs. Appendix F shows
the rental duration of plant and machinery and the description of tasks.

Using Reinforced Concrete (RC) 10 units as an example, the estimation of lorry’s rental duration for
transport of different materials were recorded in the table. Rental for the crane was estimated to
start from the construction of the first floor to the end of the project. This was the time when the
crane was needed to lift the materials to the first floor. The rental for JVC excavator was estimated
to start from the beginning of the project until the end of soil compaction. For other machineries
such as drop hammer pile driver, there was no rental for the machine. The cost was bsed on the
numbers of piles that had been drive.

3.3.4 TIME, COST, AND QUALITY ANALYSIS

The analysis of data was based on the project management perspective, time, cost and quality. With
the data gathered from the case study, detailed analysis on cold-formed steel construction and
reinforced concrete construction were carried out.

3.3.4.1 Cold-Formed Steel

(a) Time Analysis

The Gantt chart was used for time analysis and Microsoft Project were used to develop the schedule
for this construction. Work Breakdown Structure (WBS), a very useful tool to specify the project
activities was used in order to break the project into components with its identifiable and
manageable activities or tasks.

The cold-formed steel frame detached house would be designed. The time used for framing the
house was estimated. It was based on a pilot project, an estimation and roof renovation project in
Kuching, Sarawak. So the estimation for the construction would be factual data. Besides, the
experienced local cold-formed steel manufacturer and contractor were consulted in order to make
the estimation more reliable and effective.

(c) Cost Analysis

Both direct and indirect cost for the cold-formed steel structure were considered in the estimation.
The estimation rates for the direct and indirect costs were based on the recent market price in
Sarawak. The direct cost included the components of material, labor, plant and equipment, and
management, engineering and supervisors costs. The indirect costs included corporate overheads,
risk ad opportunity cost。 The market price were obtained from material suppliers, contractors, site
engineers and consultant engineers.

(i) Material Cost

For the cold-formed steel structures, the material costs considered in this research were cold
formed steel member, concrete, formwork, reinforcement steel bar, RC pile, finishes, walls and
roofing material costs. The material take-off was based on the designs. The cold-formed steel
material costs were provided by the local supplier and contractor. A total of 5% wastage were
considered in the estimation.

(ii) Labour Cost

The supply of labour (general and experienced) was arranged in accordance to the needs on site.
Different labourers were arranged to do the works everyday. The unit cost of labour took into
account the wages or salary payable to the employee and “non-productive” time. By knowing the
total labour hours and the wages rate, the total labour cost can be estimated.

The project would operate 6 days per week and 8 hours per day. Extra working hours would be
charged on 1.5 times from the hour rate and public holiday or Sunday would be charged 2 times the
basis rate.

(iii) Plant and Equipment Costs

The usage duration for each machineries was estimated in accordance to the pilot project. All the
machineries had a cost components expressed as cost per time unit (hour, day, shift, week etc.) or
lump sum project cost.

(iv) Management, Engineering and Supervision Costs

This is the cost for planning, organizing, leading and controlling of an engineering project requiring
the deployment of professional and skilled personnel to ensure that the objectives of the project are
met. The cost depends on the size, scope and complexity of the project and can vary from a few
percent to more than 10 percent during the delivery phases. The cost was estimated by interviewing
the experienced consulting engineers. Under the construction method, the management,
engineering and the supervision costs were provided by Multi Resources Group of Companies
(Kuching, Sarawak.).

(d) Quality Analysis

Quality of these two materials in construction are measured and described in eight dimensions and
different levels.

Level 1 : Basic intended use and features with no defects and complaints

Level 2 : Conformance to standards and specifications dictated by statutory bodies and designers

Level 3 : Long durability

Level 4 : Good performance, efficiency and operability

Level 5 : High reliability

Level 6 : Serviceability in various environment

Lvel 7 : Aesthetics, i.e. attractive to the eyes

Level 8 : Perceived quality deals with emotional and sensory characteristics

3.3.4.2 Reinforced Concrete

(a) Time Analysis

The Gantt chart, Microsoft Project and Work Breakdown Structure were used for time analysis. For
reinforced concrete projects, the structures existed. The time needed for construction was provided
by developer. The time estimation for all the reinforced concrete project were based on the
information provide. The experiences of the site engineers were considered as it was a common
construction method and there were sufficient source of information and reference.

(c) Cost Analysis

For cost analysis of reinforced concrete structure, direct and indirect costs were considered. Direct
costs included the components of material, labour, plant and equipment, and management,
engineering and supervision costs. Indirect costs included corporate overheads, risk and opportunity
costs. Direct costs of this project was provided by the material supplier and contractor of project.

(i) Material Cost

For the reinforced concrete structure, the material costs estimated in this research were concrete,
formwork, reinforcement steel bar, RC piles, finished, walls and roofing material costs. By knowing
the quality of material used for the project, the cost could be determined from local supplier.

(ii) Labour Cost

The supply of labour (general and experienced) was arranged in accordance to the needs on site.
Different categories of labourers were arranged daily to do the works. The unit cost of labour was
the local market rate but it took into account the wages or salary payable to the employee and
‘Non-productive’ time.

(iii) Plant and Equipment Costs

Major tools and machinery required are one crane, one excavator and one drop hammer pile driver.
All the machineries had a cost component variously expressed as cost per time unit (hour, day, shift,
week etc) and lump sum project cost. In order to know the machinery cost, the durations of
machineries must be marked.

(iv) Management, Engineering and Supervision Costs

The cost depends on the size, scope and complexity of the project and can vary from a few project
to more than 10 percent during the delivery phases. For this construction method, the
management, engineering and supervision cost would be provided very experienced consultant
engineers. It would be accurate because reinforced concrete construction is a commonly used
method in Malaysia and most of the engineers are familiar with it.

(d) Quality Analysis

Quality of the reinforced concrete structure can be measured and described in eight dimensions and
different levels as described in the previous paragraphs.

3.3.5 Comparison Analysis

After the analysis of the projects, both the results of cold-formed steel construction and reinforced
concrete construction on terms of time, cost and quality analysis will be compared. This research
compared each perspective in detail in order to determine the advantages and disadvantages of the
construction methods in management perspective.

For time analysis, the construction period were compared. This helped determine which
construction method would be more time saving. The direct and indirect costs were also compared.
For the cold-formed steel project, a few options were designed for comparison by using different
types of finished and wall materials. From quality point of view, the comparisons were conducted
using the eight dimensions of different levels.

3.3.6 Project Cost Projection

As mentioned earlier, some existing reinforced concrete houses projects were provided by the
Sarawak Housing Development Corporation. These projects comprised of concrete houses of
different sizes of development. The sizes of 1 house, 10 houses, 20 houses, 60 houses, 120 houses,
180 houses, and 240 houses were studied. The actual cost and duration for the projects were
determined. The cost included the material, labour, machinery and management costs. For the cold-
formed steel project, the houses were used for projecting the cost and times of houses of houses in
different sizes. The total cost and time needed for this project were compared with the reinforced
concrete residential project.