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Table of Contents

Table of Contents........................................................................................................................i

List of Figures...........................................................................................................................iii

List of Tables............................................................................................................................iii

Abbreviations.............................................................................................................................v

Acknowledgement....................................................................................................................vi

CHAPTER ONE........................................................................................................................1

INTRODUCTION..................................................................................................................1

1.1.0 Background..........................................................................................................1

1.2.0 Aim of Study........................................................................................................3

1.3.0 Objectives of Study..............................................................................................3

1.4.0 Methodology........................................................................................................3

1.5.0 Scope and Limitation...........................................................................................4

1.6.0 Organization of Report.........................................................................................4

CHAPTER TWO.......................................................................................................................6

LITERATURE SYNTHESIS.................................................................................................6

2.1.0 Introduction...............................................................................................................6

2.2.0 Problem Identification...............................................................................................6

2.3.0 Wall Partitioning Systems.........................................................................................8

CHAPTER THREE..................................................................................................................14

RESEARCH METHODOLOGY.........................................................................................14

3.1.0 Introduction........................................................................................................14

3.2.0 Research Approach.................................................................................................14

3.3.0 Research Process.....................................................................................................14

CHAPTER FOUR....................................................................................................................17
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RESEARCH FINDINGS.....................................................................................................17

4.1.0 Introduction.............................................................................................................17

4.2.0 Within Case Analysis..............................................................................................17

4.3.0 Overall Results........................................................................................................30

4.4.0 Analysis of Questioner Survey................................................................................37

4.6.0 Analysis of Interviews.............................................................................................44

4.7.0 Discussion...............................................................................................................48

CHAPTER FIVE......................................................................................................................49

CONCLUSION....................................................................................................................49

5.1.0 Implications for Construction Industry...................................................................50

5.2.0 Limitation of Research Study..................................................................................51

5.3.0 Further Research.....................................................................................................51

REFERENCES.........................................................................................................................52

APPENDIX A: INTERVIEW GUIDELINES.........................................................................55

APPENDIX B: PHOTOGRAPHS OF FIELD RESEARCH...................................................57

APPENDIX C: EXAMPLE INTERVIEW TRANSCRIPT.....................................................61

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List of Figures
Figure 1: Conventional wall partitions and ACOTEC wall partitions (MABETON 2016)......3
Figure 2: Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Project A)................................................................................................................................20
Figure 3: Overall Wastage of Each Method (Project A)..........................................................20
Figure 4: Construction Speed of Brick Wall and ACOTEC Wall (Project A)........................22
Figure 5: Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Project A)................................................................................................................................26
Figure 6: Overall Wastage of Each Method (Project B)..........................................................26
Figure 7: Construction Speed of Brick Wall and ACOTEC Wall (Project B).........................28
Figure 8: Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Overall)...................................................................................................................................30
Figure 9: Avg. Wastage............................................................................................................31
Figure 10: Different Types of Waste Generated from Plastering (Overall).............................31
Figure 11: Avg. Coverage Area per Labour Day.....................................................................33
Figure 12: Avg. Labour Cost per Square Meter.......................................................................34
Figure 13: Actual view of Project A........................................................................................35
Figure 14: Project A (3D Design)............................................................................................35
Figure 15: Floor Plan of Project A...........................................................................................35
Figure 16: Floor Plan of Project B...........................................................................................36
Figure 17: Actual view of Project B........................................................................................36
Figure 18: Project B (3D design).............................................................................................36
Figure 19: Structure of Questioner Survey..............................................................................37

List of TablesY
Table 1: Material Properties of ACOTEC Panels (Nanayakkara 2014)..................................10
Table 2: Compressive Strength of a Panel (Nanayakkara 2014).............................................11
Table 3: Compressive Strength Results (Nanayakkara 2014)..................................................12
Table 4: Flexural Strength of Panels (Nanayakkara 2014)......................................................12
Table 5: Water Absorption and Moisture Content of Specimens (Nanayakkara 2014)..........13
Table 6: Wastage of Brick and ACOTEC Panel (Project A)...................................................18
Table 7: Wastage of Plastering and ACOTEC Panel (Project A)............................................19

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Table 8: Labour Involvement & Coverage of Work (Project A).............................................21
Table 9: Labour Cost of ACOTEC panel and Brick Wall Partioning (Project - A)................23
Table 10: Wastage of Brick & ACOTEC Panels (Project - B)................................................24
Table 11: Wastage of ACOTEC Panel and Plastering Work (Project – B).............................25
Table 12: Labour Involvement & Coverage of Work (Project B)...........................................27
Table 13: Labour Cost of ACOTEC panel and Brick Wall (Project - B)................................29
Table 14: Background of Interviews........................................................................................44
Table 15: Overall Coding Structure of Interviews...................................................................45

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Abbreviations
VE – Value Engineering

VM – Value Management

N/A – Not Applicable

Avg. – Average

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Acknowledgement
I would like to express my thankfulness to the ICBT and Sheffield Hallam University, UK for
giving me this opportunity to write up this dissertation as a part of completion of my degree
in Quantity Surveying and Construction Management. I would like to convey special
gratitude towards our lecturer Mr. S. K Weragoda and my supervisor Mr. Nadeeka
Jayasooriya to guide me through in this research in many aspects. I also take this opportunity
to thank my parents and colleagues who supported me throughout this research and made me
possible completing this project successfully on time. I am glad I took this opportunity to
thank each and every one who made available helping me in numerous ways on this task.

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CHAPTER ONE
INTRODUCTION
1.1.0 Background

There is an extreme requirement for substitute construction methods, and technologies that
can reduce waste and energy consumption during the construction process and throughout the
life-cycle of the building (Elsevier Ltd 2013). Most of the Sri Lankan condominium projects
are carried out using conventional brick wall partitioning system. The conventional
brickwork required a lot of skilled labour and time. A new survey has showed that the
Government of Sri Lanka should concern about the shortage of skilled and unskilled work
force in some certain industries including the building construction sector (The Sundaytimes
Sri Lanka 2014). Due to the high demand for residential apartment in Colombo area the
developers need to carry out few projects at a time. But shortage of labour and time
consuming for conventional construction work, it has been rather difficult to complete these
projects on time. Through an informal survey I carried out recently through few masonry
subcontractors, they said, it was extremely difficult to find unskilled and skilled workers for
their teams.

The wastage factor is very high for conventional brickwork construction. It can be due to
transport, storing, handling and poor workmanship. For calculating wastage of brickwork,
there is no such particular method. Generally, to calculate brick wastage and breakage, 5
percent of allowance is added to the estimated quantity that is to be delivered to the
construction site. Condition of the construction site and the experience level of the labour are
directly effect on the amount of wastage (The Brick Industry Association 2009).

Another factor is in condominium projects around the Colombo area is space. The prices of
the lands are very expensive and increasing day by day. It is reported that nearly 25 percent
increment of the land prices throughout the previous few months and after the November
budget. This was happened due to the high demand for lands throughout the past 18 months
especially for the high end residential properties (The Sundaytimes Sri Lanka 2015).

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The ACOTEC wall panels that are going to be discussed under this research have the exact
dimensions and extremely uniform surface which ensure that no plastering is required.
Additionally, the thin structure of these panels allows added floor space for other
commitments in a building (Elematic 2016).

Sri Lankan construction industry faces a significant rate of delays in project delivery. The
causes of delays in construction in Sri Lankan have been identified and have been addressed
individually by stakeholders. However, the delay occurs in almost all projects in Sri Lanka
continuously (Jayalath 2010). Hence, there should be proper controlling methods to eliminate
these delays systematically. As in this research there should be one of the two main problems
can be identified that is the shortage of labour and time consuming on conventional building
construction methods. In order to overcome the project delays, it is necessary to find
solutions with respect to the above two problems.

It is intended to evaluate and rationalize the applicability of ACOTEC wall panels over
conventional brickwork. In this case there should be proper reasons to determine why
choosing ACOTEC panels over traditional methods are beneficial. It should be discussed till
the depth in terms of cost, quality and time.

There were several reasons for me to select this topic as my research project. One reason is an
incident that took place recently which was discussed with the project team and directors of
our company. It is to use new internal wall paneling system rather than using traditional brick
construction to speed up the construction process. These panels are made out of concrete and
have very smooth surface which required no plaster work. According to the manufacturers’
and suppliers’ statements, this method is seven times faster than the conventional brickwork.
Therefore, this research is to find out the practicability of using ACOTEC panels in
condominium projects in Sri Lanka by using some advance research techniques.

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Figure : Conventional wall partitions and ACOTEC wall partitions (MABETON 2016)

1.2.0 Aim of Study

Investigate the applicability of ACOTEC panels for project delays, shortage of labour,
material wastage and cost overrun due to conventional brick wall partitioning system in
condominium projects in Sri Lanka.

1.3.0 Objectives of Study

 To study the wastage, labour involvement and quality of brickwork and ACOTEC
wall partitioning systems.
 To evaluate & discuss the cost effectiveness of ACOTEC wall partitioning systems
over conventional brickwork.

1.4.0 Methodology

1.4.1.0 Literature Survey and Review:

Extensive literature survey and analysis is to recognize innovative wall partition systems and
its effectiveness in terms of cost, quality and time throughout the construction progression by
referring journals, books, theses etc.

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1.4.2.0 Case Studies:
Case study approach is to be implemented so as to do an examination of the labour
arrangements, wastage, quality and time impact on construction of ACOTEC partition
systems.
1.4.3.0 Direct Observation:
Direct observations to be done within case studies to inspect the wastage levels, time
consumption, quality of work, labour requirement, etc.
1.4.4.0 Structured Interview & Questionnaires:
Structured interviews to be done to identify the professional preference and awareness of
these innovative wall partition systems.

1.5.0 Scope and Limitation


This study is limited to a reputed property development company based on Colombo and only
suite to Sri Lankan context. Only two floors to be observed (3rd and 4th floor) and two projects
will be analysis due to very limited time. Direct observation is carried on one innovative wall
partitioning system (ACOTEC wall panel) system despite the fact that there are more
innovative methods that available in the market. The comparison will be done with the
records of brick masonry work with the findings of the two sites which have been observed in
this particular period.

1.6.0 Organization of Report

Chapter One: Introduction

Chapter one introduces wider research range and classifies problematic within the research
with respect to the aim, objectives, scope, methodology, and limitations of this study and also
represents the organization of this report.

Chapter Two: Literature Synthesis

Chapter two reflects the theoretic standing and problems within the research over complete
literature assessment and synthesis so as to realize and institute the implication of the
research issue and develop suggestions to report the research issue primarily to deliver
prominence for data collection.

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Chapter Three: Research Methodology

Chapter three delivers the research technique and research procedure practice within the
research. The data collection and analysis will be discussed in this chapter in a detailed
manner.

Chapter Four: Research Findings

The research findings and analyzed data constantly by within and across cases in detailed will
be discussed in chapter four.

Chapter Five: Conclusion

Chapter five draws decisions of the above study with regards to the research issues to be
addressed. Second, it clarifies applied implications of the study. Third, it discourses limits
and prospects accessible for more examination under this area of the research.

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Chapter Two Literature
Synthesis

CHAPTER TWO
LITERATURE SYNTHESIS
2.1.0 Introduction
The intention of this section is to discover the theoretic position and research matters over
inclusive literature evaluation and synthesis so as to recognize and institute the consequence
of the study problematic.

2.2.0 Problem Identification


Delays in project delivery are a significant problem that Sri Lankan construction industry
faces nowadays. The reasons of delays have been recognized and have been spoken
exclusively by industrial professionals despite the fact that almost all projects face this delay
incident in Sri Lanka continuously (Jayalath 2010). There can be numerous reasons for these
delays such poor planning and schedules, variations, financial difficulties of both the client
and the contractor, poor procurement, delays in obtaining permits, poor site management,
poor coordination, etc. but other than that the projects can be delayed immensely due to
conventional construction methods which is going to be discussed under this research study.

2.2.1.0 Shortage of Labour


Conventional brickwork required lot of skilled labour and time. The labour component has
become a very big problem at the moment in the construction sector in Sri Lanka. The
relative important index method was adopted to rank the GIUSCS and effects in the order 01"
their importance and "Improper project management by the contractor" was recognized as the
core reason. Other reasons for the project delays were recognized as "Shortage of” labour"
(Smarakoon 2009). Thus, there should be proper methods that require less labour
involvement for the construction works while increasing the productivity.

The above problem has been an extreme problem throughout the past few years and getting
worse. It is important to find a proper solution for this problem as soon as practicable.
Without the labour capacity, it is not only construction industry but also other types of
industries are facing numerous problems as they cannot meet the required demand within the
time frame.

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Chapter Two Literature
Synthesis

The most of the condominium developers are willing to offer high rates for labours to attract
them for their works due this shortage of labour. But it is regrettable, even for high rates they
find it difficult to tackle required labour for construction work especially for masonry,
formwork and reinforcement work.

2.2.2.0 Lack of Value Engineering (VE) Practices


In Sri Lanka, Value Engineering (VE) does not practice properly. Most of the professional
think it as cost cutting process. VE is a process that improves value of a product without
harming its basic functional requirement at a lower cost. Thus, adopting innovative methods
over conventional construction methods is a kind of value engineering approach that should
be practiced within the industry. As Stated in the report by (Perera, Karunasena and
Selvadurai 2003), they reveal that “there was very little evidence on application of VM in the
construction industry of Sri Lanka”. Lack of awareness of construction companies regarding
VE is one of the reasons why it is not successful in Sri Lanka (Weligoda 2009). Hence, these
innovative and cost effective methods should be introduced to the industry and should
encourage applying these methods wherever necessary.

2.2.3.0 High Wastage


Wastage is a huge problem in conventional brick wall and cement block wall construction. It
can be due transport, storing, handling and poor workmanship. For calculating wastage of
brickwork, there is no such particular method. Not only brick wastage, it also includes the
wastage of cement and sand that has been using as bonding mixture (mortar) for brickwork.
Imagine a construction project without a waste management plan, I laugh, even though,
material wastage of mortar might have been taken care of, in the bill, there is still a need for
waste management plan, the absence of this document reduces profit margin (Ridwan 2013).

2.2.4.0 Poor Workmanship


The poor workmanship by the brick layers will again lead the material wastage. For an
example if the brick walls are not layered evenly, the plaster work will be more and it will
need a more plaster thickness to be applied to cover the surface properly. It will reduce the
space due to thickness of plaster, will take more time, quality will be reduced, wastage will
be maximum, and labour charges may be high.

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Chapter Two Literature
Synthesis

2.2.5.0 High Time Consumption


Conventional brick wall construction requires more time. According to discussion I had with
masonry subcontractors, they said average construction capacity of brick wall is 150 Sq.ft
from 112.5 mm thickness brick walls and less than 100 Sq.ft from 225mm thick brick walls
with the involvement of one unskilled labour and a skilled mason. ACOTEC wall panels are
easy, fast and safe to install. When comparing with traditional brick wall construction,
ACOTEC wall panels are 6 times faster to install (Elematic 2016). Hence, it is clear that these
innovative wall partitions have the potential to become a solution for project delays due
conventional wall partitioning systems.

2.3.0 Wall Partitioning Systems


When considering the wall partitioning systems there are range of materials and methods are
used in different countries as to which withstand with the weather conditions, environments
factors, availability of material, safety and also traditional building methodologies that they
have been using for long time from the early stage of their origin.

2.3.1.0 Conventional Wall Partitioning Systems


Since this research is limited to Sri Lankan context with respect to the condominium
construction development, the below two methods can be introduced as conventional wall
partition systems.

 Brick wall partitions


 Cement block wall partitions

The above methods have been using past few decades and still continuing in Sri Lanka.
Cement blocks are not widely used in condominium projects due to some certain
characteristics that the developers and clients do not approve.

2.3.1.1.0 Cement Block Wall Partitions


The cement blocks are available in different sizes and thicknesses to meet different
construction preferences and applications. The available sizes of these blocks are varying due
to different manufactures. There are mainly two types of blocks which are solid blocks and
hollow blocks.

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Chapter Two Literature
Synthesis

2.3.1.2.0 Brick Wall Partitions


The most commonly used wall partitioning for condominium projects in Sri Lanka is burnt
bricks. Due to its exceptional characteristics it has been the selection of wall partitioning by
most of the professional in the industry. The burnt bricks are available in few different sizes.
The application of this bricks are done as double layer of bricks for external walls and
dividing two apartments in the same side and the internal walls are in as single layer walls.

2.3.2.0 Innovative Wall Partitioning Systems


This is the new approach that is going to be introduced in this research. At the moment in Sri
Lanka, construction companies do not use these innovative methods to improve their
construction projects. In this research light weight concrete blocks and concrete wall panels
(ACOTEC wall panels) will be discovered with its characteristics of these materials,
performances, ease of installation, advantages and disadvantages.

2.3.2.1.0 Light Weight Concrete Blocks


Light weight concrete blocks are available in different sizes have smooth surface that
required no plaster work. According to some manufactures they called this method as “Thin
Joint Construction”. Thin Joint construction is a masonry wall construction technique which
replaces conventional 10mm cement sand mortar joints with 2-3mm joints using a special
adhesive mortar. This technique of 'gluing' blocks together results in a significantly faster
build build time, less waste, less materials and plant required on site and walls with improved
u-values and air-tightness (THOMAS AMSTONG 2010). This method is widely used in the
UK and European construction market for housing projects.

2.3.2.2.0 Concrete Wall Panels


Concrete wall panel system is a precast system that can come with different heights to meets
the requirement for the site situation. This panels are also light weight and easier to install
and have a very good modular characteristics which will be discussed further in research
literature under material properties of ACOTEC wall panels. Same as lightweight concrete
blocks this method does not require plaster work as well. Manufacturing process is also easy.
Highly automatized lines produce 80 m2 components per hour with only 2 or 3 operators
(MABETON 2016).

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Chapter Two Literature
Synthesis

2.3.2.3.0 ACOTEC Wall Panels


Under this paragraph, it is expected to give an introduction about the ACOTEC panels and its
characteristics.
In Sri Lanka, there is only one supplier who carries out the production of these panels up-to-
date. The capacity of the production is around 300 to 350 panels per day which covers almost
432 m2. The panels must be required to be cured for 28 days from the date of the production.
The main materials that are used to produce these panels are cement, sand and crushed metal.
The panels are comes with same width while there are three different heights which are 2.4m,
2.6m & 2.7m. The panels are delivered to sites by containers that can carry around 150 panels
at a time and a crane or construction lift is required to lift the panels vertically into floor
levels.

2.3.2.3.1.0 Material Properties


Material properties of ACOTEC panels are given in the Table 1.

Table : Material Properties of ACOTEC Panels (Nanayakkara 2014)

  Panel Thiknes
75mm 100mm 140mm
Weight 120 kg/m2 150 kg/m2 190 kg/m2
Concrete Density 2200 kg/m3 2200 kg/m3 2200 kg/m3
Cube Compressive Strength 30-35 N/mm2 30-35 N/mm2 30-35 N/mm2
Fire Resistance 120 mins 150 mins 180 mins
Sound Insulation 41dB 44dB > 44dB
Thermal Resistance 0.4m2K/W > 0.4m2K/W > 0.4m2K/W
Sectional Compressive 20 N/mm2 > 25 N/mm2 > 30 N/mm2
Strength
Load that can be hung 200 kg 300 kg 350 kg
Flexural Strength 1.08 N/mm2 - -
Loading Test 299.7 kN - -

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Chapter Two Literature
Synthesis

2.3.2.3.2.0 Test Results


ACOTEC panel has been tested by the University of Moratuwa as per the request of the
manufacture. The tests have been performed to determine flowing properties of the ACOTEC
panels.

1. Load carrying capacity of the panel under uniaxial compression


2. Compressive strength of specimens extracted from ACOTEC panels
3. Flexural strength of panels
4. Water absorption
5. Shrinkage of ACOTEC panels

2.3.2.3.2.1.0 Load Carrying Capacity of the ACOTEC Panels


In order to determine the load carrying capacity of an ACOTEC panel, it is necessary to test a
3m high panel. Since the maximum height of a panel that can be tested with the available
facilities in the laboratory is limited, a panel was cut approximately to a 2.4m and loaded to
find the load carrying capacity under uniaxial compression. To obtain uniform load
distribution, top and bottom edges were capped 1:1 cement mortar. The results obtained are
given in Table 2.

Table : Compressive Strength of a Panel (Nanayakkara 2014)

ACOTEC panel Date of Testing Maximum Load Compressive


Dimensions L×W×T (mm) Applied (kN) Strength (N/mm2)
2433×602×91 29/09/2014 299.7 5.47
(with 7 holes of øav=52.5mm)

2.3.2.3.2.2.0 Compressive strength of specimens extracted from ACOTEC panels


In order to check the crushing strength, five small specimens were cut from ACOTEC panels.
These specimens were capped with 1:1 cement: sand mortar on both the top and bottom sides
as in testing of cement blocks for compressive strength. Standard size (71×71×71 mm)
mortar cubes were casted to heck the mortar strength. After reaching the required strength of
mortar, all specimens were crushed using 200Ton compression testing machine. Compressive
strength results are given in Table 3.

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Chapter Two Literature
Synthesis

Table : Compressive Strength Results (Nanayakkara 2014)

Specime Date Length Width Height Compressive


n ID Nr (mm) (mm) (mm) Strength
(N/mm2)

1.00 9/25/2014 359.00 89.00 217.00 9.15


2.00 9/29/2014 359.00 91.00 221.00 5.88
3.00 9/29/2014 358.00 90.00 2219.00 8.28
4.00 9/29/2014 359.00 91.00 216.00 6.12
5.00 9/29/2014 359.00 92.00 220.00 6.11
Average Compressive Strength 7.11

2.3.2.3.2.3.0 Flexural strength of panels


To determine the flexural strength when failure is parallel to transverse direction, ACOTEC
panel were tested under four point loading pattern. Table 4 gives the flexural strength of these
panels.

Table : Flexural Strength of Panels (Nanayakkara 2014)

Panel Nr Flexural Strength


(N/mm2)
1 1.08

2 0.8

2.3.2.3.2.4.0 Water Absorption and Moisture Content


Water absorption test was carried out in accordance with SLS 855: Part II: 1989. The results
obtained for three specimens for extracted from two panels are given in Table 4. For the
comparison of the specimen values for blocks, absorption, kg/m3 was also calculated and
included in Table 5. The moisture content of the specimens tested is higher than the
maximum specified value given in SLS 855: Part I: 1989 (i.e. 40%) for blocks. However,
absorption of the specimens tested is less the maximum specified values given in SLS 855:
Part I: 1989 (i.e. 240 kg/m3)

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Chapter Two Literature
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Table : Water Absorption and Moisture Content of Specimens (Nanayakkara 2014)

Specime Size (mm) Water Absorption Moisture


n Nr Absorption kg/m3 of net Content
(%) Volume (%)

1.00 236 × 91 × 201 7.50 125.00 73.40


2.00 236 × 90 × 198 8.00 132.90 71.40
3.00 237 × 90 × 198 7.60 76.60 76.60

2.3.2.3.2.5.0 Comments
The compressive strength results obtained from previous research studies on brickwork
column specimens and walls were in the range 1.0 ~ 1.3 N/mm2 depending on the mortar
mixes used. The compressive strength of ACOTEC panel tested was 5.47 N/mm 2 which is
very much higher than the strength of normal brick walls (Nanayakkara 2014).

From the previous studies, it was found that the flexural strength for local brickwork were in
the range of 0.02 ~ 0.25 N/mm2 when failure is parallel to bed joints and in the range of 0.173
~ 0.29 N/mm2 when failure is perpendicular to bed joints These strength values are relatively
low when compared with the flexural strength of ACOTEC panels tested (Nanayakkara
2014).

Furthermore, flexural strength for block masonry given in BS 5628: Part I: 1992, are in the
range 0.2 ~ 0.25 N/mm2 (when failure is parallel to bed joint) and 0.4 ~ 0.6N/mm2 (when
failure is perpendicular to bed joints). The ACOTEC panels tested had much higher flexural
strength (0.8 & 1.08 N/mm2) than flexural strength of block masonry given in BS 5628: Part
I (Nanayakkara 2014).

The water absorption of ACOTEC samples tested was in the range of 7.5% ~ 8.0%.
According to SLS 39: 1978 specification, for normal clay brick (Type 2), the water
absorption should not exceed 28%. For blocks, SLS 855: Part I: 1989 specifies that
absorption should not exceed 240 kg/m3. The absorption of ACOTEC specimens tested was
well below this specified value (Nanayakkara 2014).

The moisture content (based on maximum possible moisture in the sample) of the samples
tested is higher than the maximum specified value given in SLS 855: Part I: 1989 (i.e. 40%)
for blocks (Nanayakkara 2014).
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Chapter Three Methodology

CHAPTER THREE
RESEARCH METHODOLOGY
3.1.0 Introduction
The purpose of this episode is to explain the complete research procedure of this research in
comprehensive routine.

3.2.0 Research Approach


Investigation methods are about establishing research movement, with the assembly of data
in ways that are most likely to accomplish the study aim (Easterby-Smith et al., 2002). This
research study involved case study research approach in order to undertake an in-depth
exploration regarding the labour consumption, quality and wastage quantification to compare
the cost effectiveness between conventional and innovative wall partitioning systems.

3.3.0 Research Process


The investigation course of this research, which is established on case study research method,
encompassed subsequent stages: initial impetus; literature review; problem statement; case
study design; data collection; data analysis; and write up. The following subdivisions survey
this classification in illumination the entire research procedure of this study.
3.3.1.0 Initial Impetus
The original impetus to bring out this research is primarily obsessed as a result of a chance
set by the ICBT on behalf of Sheffield Hallam University for fulfillment of dissertation study
for final year students for the award of gradation. Thereafter, study topic was activated by the
supervisor under ‘Feasibility study of adopting innovative wall partitioning systems in
condominium projects in Sri Lanka’.

3.3.2.0 Literature Review


The literature assessment was begin with contextual reading which was directed to recognize
wider study area of adopting innovative wall partition systems to improve construction speed,
reduce wastage and better quality and also as solution for shortage of labour in Sri Lankan
construction industry. The inclusive literature assessment was directed to discover the
conjectural standing and investigation matters such as definitions, types of wall partition
systems, projects delays, labour involvement, poor workmanship, value engineering, cost
overrun, waste generation, waste quantification methods, holes of this area and institute the

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Chapter Three Methodology

implication of research problem. The literature exploration was prepared in publications such
as books and journal articles, web publications, thesis, dissertations available in common
databases and University library.
3.3.3.0 Research Problem Statement
The research problem emerged as “how ACOTEC wall partitioning system can be adopted as
solution for projects delays and high wastage?” through background study. This research
problem was reinforced concluded a inclusive literature appraisal.
3.3.4.0 Case Study Design
Two case studies are carried out in ongoing residential construction sites of reputed property
development organization, based on access and time limitations. In this case study design
there are few main aspects has been considered; coverage of work done with respect to the
number of labour involvement, wastage and labour cost. The next stage of the research
procedure which established on case study technique was to adopt on research technique for
data collection.

3.3.5.0 Data Collection


3.3.5.1.0 Data Collection Technique
Facilitate discernment was castoff as the standard data collection system for this survey.
Genuine explanation behind direct recognition is to set up relationship among the events, in
finding the reasons after them and to inspect wonder and in this manner in testing of the
hypothesis methodically (Thakur, 1993). Key determination of semi-structured interview is
basically to cooperate confident evidences that the researcher already reflects that have been
recognized (Yin, 1984). Having chosen direct observation and semi-structured interviews as
data gathering strategies, the following areas introduce point by point data of such
techniques.

3.3.5.2.0 Approach to Data Collection


Meanwhile this investigation study was grounded on direct observation in ongoing residential
construction sites as the main data collection method, it was selected only two floors of the
masonry work or partitioning work of the building for the direct observation. There were
numerous explanations exaggerated to this choice. Erection of a building needs lengthier
time. But for the study only very limited time is available. Therefore, it is hard to perceive
entire building work during this limited time. The observations to be focused on labour
requirement, coverage area of work, time consumption, wastage and quality of workmanship.

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Chapter Three Methodology

3.3.5.3.0 Interview Structure and Process


The interview guidelines of this review were predominantly intended to capture the
information towards the goals of the research and the questions were produced in light of the
literature survey. The interview guidelines (see Appendix A) contained 11 questions.

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Chapter Four Research
Findings

CHAPTER FOUR
RESEARCH FINDINGS
4.1.0 Introduction
The aim of this chapter is to present the research findings of the empirical investigation. First,
this chapter will present within-case analysis of two case studies which identifies labour
involvement in conventional and innovative wall partitioning systems, coverage of work with
respect to labour involvement, quality of work, wastage, advantages and limitations of each
system. Second, it will present overall result in relation to traditional brick wall construction
and ACOTEC wall panel construction systems with respect to the above identified aspects.
Third, it will present the analysis of questioner survey and interviews in detailed in order to
formulate solutions to mitigate construction delays, wastage and poor workmanship due to
conventional wall partitioning systems and finally, it will be attempting to prove hypothesis
formulated through a discussion across the two case studies.

4.2.0 Within Case Analysis


4.2.1.0 Case Study 01
Project – A
Table-6 and Table-7 represent the levels of waste measured during the observation of project
A with relate to the brickwork and ACOTEC panel installation. Table-7 clearly shows that
there is no plastering work involved for the partition walls where the ACOTEC panels were
used. Hence, wastage due to plastering is zero level for ACOTEC panels while it was 1.19%
for brick wall construction.

As shown in the Table-6 the waste level of brickwork and ACOTEC panels due to different
cases as analyzed, brick has considerable accumulation of waste which is 4.26% higher than
the ACOTEC panels. Table-7 illustrates that almost 0% wastage due to transport, transits
within the site, fixing and residue waste while considerable wastage due to cutting was
reported for ACOTEC panel which is 73% of total waste produced.

Table-8 presents the labour involvement and the coverage of area during the observation of
project A under each method. According to the Table-8, 136.66 m2 were covered using
ACOTEC panels with 24 labour days which approximately 6 m 2/ (Labour Day). But it took
48 labour days to cover 91.95m2 brickwork with the both side plaster work which is

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approximately 2 m2/ (Labour Day). Hence, according to the figures of project A ACOTEC
panel installation is 3 times faster than the brick wall partitioning work.

Table : Wastage of Brick and ACOTEC Panel (Project A)

  Composition of Waste Types of Waste (m3)


Method Waste Qty Percentage Delivery Site Cutting Fixing Residue
Material (m3) Waste Transit Waste Waste Waste
Waste

ACOT ACOTEC 0.42 95.45% 0.02 0.03 0.32 0.05 -


EC panels
Panel Glue 0.02 4.55% 0 0 0 0.01 0.01
Total 0.44 100.00% 0.02 0.03 0.32 0.06 0.01
Actual Volume of Construction 14.29
Total Wastage for 1m3 0.03
Percentage of Waste 3.07%
 
Brickw Brick 0.54 67.58% 0.1 0.14 0.18 0.12 -
ork Mortar 0.26 32.42% - - - 0.11 0.15
Total 0.80 100.00% 0.1 0.14 0.18 0.23 0.15
3
Actual Volume of Construction m 10.90
Total Wastage for 1m3 0.07
Percentage of Waste 7.33%

The figures that have shown in Table-6 are based on the waste incurred during both brick
wall constriction and ACOTEC panel installation work. It has been carefully categorized by
means of how these wastes were generated at site, whether it was due to cutting, handling,
etc. The collections of wastes were cautiously put into a 1m 3 box made out of plywood and
timber frame to measure the volume of waste properly (see Appendix B). The area of actual
volume is the measured area for brick and panels including mortar bonds, bonding material,
glue, etc. which multiply by the thickness of the walls. Then the total wastes calculated in
both methods were divided by the actual volume of construction to find the percentage of
waste of each system.

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In that way all the figures have been systematically recorded in a excel spread sheet. Then it
was entered in a table to show all details in a proper manner to understand the overall results
of each method under Project A. Figure-2 represent the same for easy comparison of waste
generated in the both systems and type of waste. The summary of overall wastage of
ACOTEC panel and brick wall construction is shown in Figure-3 in the respective project.

Table : Wastage of Plastering and ACOTEC Panel (Project A)

  Composition of Waste Types of Waste (m3)


Method Waste Qty Percentag Delivery Transit Cutting Fixing Residue
Material (m3) e Waste Waste Waste Waste Waste

ACOTEC ACOTEC N/A 0.00% 0 0 0 0 0


Panel panels
Total N/A 0.00% 0 0 0 0 0
Actual Volume of Construction 14.29
Total Wastage for 1m3 0.00
Percentage of Waste 0%
 
Plastering Mortar 0.13 100.00% - - - 0.07 0.06
Total 0.13 100.00% 0 0 0 0.07 0.06
Actual Volume of Construction 10.90
Total Wastage for 1m3 0.01
Percentage of Waste 1.19%

In the Table-7, there is no calculation was needed for the areas where the ACOTEC panels
were installed. However, it was necessary to relate the wastage incurred during the plaster
work that is to make the brick surface smooth and prepare for the putty and paint work.
ACOTEC panels are ready for the putty and paint work directly. In the same way, the
collections of wastes were cautiously put into a 1m 3 box made out of plywood and timber
frame to measure the volume of waste properly (see Appendix B). The area of actual volume
is the measured area for brick and panels including mortar bonds which multiply by the
thickness of the walls.

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2.50%
2.24%
2.11%
2.00%
1.65%
1.50% 1.37%
1.28%

1.00% 0.92%

ACOTEC
0.50% 0.42% Brick
0.14% 0.21%
0.07%
0.00%
te te te te te
as as as as as
yW sit
W gW gW eW
er n n in u
eliv Tr
a u tti Fix esid
D e C R
Sit
al
ern
t
In

Figure : Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Project A)

8.00%
7.33%
7.00%

6.00%

5.00%

4.00% ACOTEC
Brick
3.07%
3.00%

2.00%

1.00%

0.00%
Overall Wastage

Figure : Overall Wastage of Each Method (Project A)

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Chapter Four Research
Findings

Table : Labour Involvement & Coverage of Work (Project A)

Method Date Skilled Unskilled Nr of Coverage Actual


labour labours Panels Area Coverage
s (Nr) (Nr) (m2) (m2)
Acotec 12/14/2016 1.00 3.00 15.00 23.70 21.22
Panel 12/15/2016 1.00 3.00 15.00 23.70 21.96
12/16/2016 1.00 3.00 16.00 25.28 23.16
12/17/2016 1.00 3.00 16.00 25.28 22.66
12/18/2016 1.00 3.00 18.00 28.44 26.43
12/19/2016 1.00 3.00 15.00 23.70 21.23
Total 6.00 18.00 95.00 150.09 136.66
 
Method Date Skilled Unskilled Nr of Coverage Actual
labour labours Bricks Area Coverage
s (Nr) (Nr) (m2) (m2)
Brickwork 12/12/2016 3.00 3.00 1290.00 24.81 22.30
(Brick 12/13/2016 3.00 3.00 1310.00 25.19 23.00
Laying) 12/14/2016 3.00 3.00 1280.00 24.62 22.40
12/15/2016 3.00 3.00 1280.00 24.62 24.25
Brickwork 12/27/2016 4.00 2.00 N/A N/A N/A
(Plastering 12/28/2016 4.00 2.00 N/A N/A N/A
Both Sides) 12/29/2016 4.00 2.00 N/A N/A N/A
12/30/2016 4.00 2.00 N/A N/A N/A
Total 28.00 20.00 N/A N/A 91.95

Figure 4 represents the analysis of work done over labour involvement referred to the table 8
for the easy understanding. Cumulative work done of both systems is shown clearly. As it is
shown, in brickwork series, work done will be same even though there was labour
involvement. The reason is plastering work. Brick walls need to be plastered but ACOTEC
walls do not required a plaster work.

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Chapter Four Research
Findings

70

60

50
Area Covered (m2)

40

30 ACOTEC
Brick

20

10

0
0.00 10.00 20.00 30.00 40.00 50.00 60.00
Number of Labour Days

Figure : Construction Speed of Brick Wall and ACOTEC Wall (Project A)

According to the figures of Table-8, if the labours used for brickwork could have been used
for ACOTEC panel work, they could have completed approx.280m 2 which is a massive work
done.

Labour cost of each method is representing by the Table-9. To cover up 137.97m 2 of internal
wall area, it took only Rs.34,200.00/- for ACOTEC panels while it took 76,400.00/- to
construction of brick wall partitioning cost including the both side plaster work. The Labour
cost of brick wall construction is approximately 330% is greater the installation of ACOTEC
panel as per the observation records of project A.

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Table : Labour Cost of ACOTEC panel and Brick Wall Partioning (Project - A)

Project - A

Item Description Unit Qty Rate Amount


Nr
1.00 Labour cost of installing ACOTEC        
panels
1.01 Skilled Labour day 6.00 1,800.00 10,800.00
1.02 Unskilled Labour day 18.00 1,300.00 23,400.00
Total Labour cost of installing ACITEC 34,200.00
panels
Total Coverage of work m2 136.66
  Rate per 1m2 Rs. 250.25
           
           
2.00 Labour cost of brick wall construction        
  Brick Laying        
2.01 Skilled Labour day 12.00 1,800.00 21,600.00
2.02 Unskilled Labour day 12.00 1,300.00 15,600.00
Total for brick laying 37,200.00
           
  Plastering        
2.03 Skilled Labour day 16.00 1,800.00 28,800.00
2.04 Unskilled Labour day 8.00 1,300.00 10,400.00
Total for Plastering both sides 39,200.00
           
  Total cost of brick wall construction      
with plastering both sides of the walls 76,400.00
  Total Coverage of work m2   91.95
           
Rate per 1m2 Rs. 830.88
           

Note: - Actual cost of panel installation was higher as it was not direct labour. The above
costs were based on the prevailing rates of the market in Colombo, Sri Lanka and as per the
labour analysis at the observed site.

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4.2.2.0 Case Study 02


Project – B

Table-10 and Table-11 represent the levels of waste measured during the observation of
project B with relate to the brickwork and ACOTEC panel installation. Table-11 clearly
shows that there is no plastering work involved for the partition walls where ACOTEC panels
were used. Hence wastage due to plastering is zero level for ACOTEC panels while it was
2.60% for brick wall construction. As shown in the Table-10 the waste level of brickwork
and ACOTEC panels due to different cases as analyzed, brick has considerable accumulation
of waste which is 2.5% is higher than the ACOTEC panel. Table-10 illustrates that almost
0% wastage due to transport, transits within the site, fixing and residue waste while
considerable wastage due to cutting was reported for ACOTEC panel which is 77% of total
waste produced.

Table : Wastage of Brick & ACOTEC Panels (Project - B)

  Composition of Waste Types of Waste (m3)


Method Waste Qty Percentage Delivery Transit Cutting Fixing Residue
Material (m3) Waste Waste Waste Waste Waste

ACOT Acotec 0.55 94.49% 0.02 0.02 0.44 0.07 -


EC
Glue 0.02 5.88% 0 0 0 0.01 0.01
Total 0.57 100.00% 0.02 0.02 0.44 0.08 0.01
Actual Volume of Construction 16.44
Total Wastage for 1m3 0.03
Percentage of Waste 3.47%
 
Brickw Brick 0.27 69.23% 0.05 0.07 0.09 0.06 -
ork Mortar 0.12 30.77% - - - 0.05 0.07
Total 0.39 100.00% 0.05 0.07 0.09 0.11 0.07
Actual Volume of Construction 6.54
Total Wastage for 1m3 0.06
Percentage of Waste 5.97%

The figures that have shown in Table-10 are based on the waste incurred during both brick
wall constriction and ACOTEC panel installation work. It has been carefully categorized by
means of how these wastes were generated at site, whether it was due to cutting, handling,
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etc. The collections of wastes were cautiously put into a 1m 3 box made out of plywood and
timber frame to measure the volume of waste properly. The area of actual volume is the
measured area for brick and panels including mortar bonds, bonding material, glue, etc.
which multiply by the thickness of the walls. Then the total wastes calculated in both
methods were divided by the actual volume of construction to find the percentage of waste of
each system.

In that way all the figures have been systematically recorded in a excel spread sheet. Then it
was entered in a table to show all details in a proper manner to understand the overall results
of each method under Project B. Figure-5 represent the same for easy comparison of waste
generated in the both systems and type of waste. The summary of overall wastage of
ACOTEC panel and brick wall construction is shown in Figure-6 in the respective project.

Table : Wastage of ACOTEC Panel and Plastering Work (Project – B)

  Composition of Waste Types of Waste (m3)


Method Waste Qty Percentage Delivery Transit Cutting Fixing Residue
Material (m3) Waste Waste Waste Waste Waste

ACOTEC ACOTEC N/A 0.00% 0 0 0 0 0


Total N/A 0.00% 0 0 0 0 0
Actual Volume of Construction 9.71
Total Wastage for 1m3 0.00
Percentage of Waste 0%
 
Plastering Mortar 0.17 100.00% - - - 0.10 0.07
Total 0.17 100.00% 0 0 0 0.24 0.18
Actual Volume of Construction 6.54
Total Wastage for 1m3 0.03
Percentage of Waste 2.60%

In the Table-11, there is no calculation was needed for the areas where the ACOTEC panels
were installed. However, it was necessary to relate the wastage incurred during the plaster
work that is to make the brick surface smooth and prepare for the putty and paint work.
ACOTEC panels are ready for the putty and paint work directly.

In the same way, the collections of wastes were cautiously put into a 1m 3 box made out of
plywood and timber frame to measure the volume of waste properly. The area of actual

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Chapter Four Research
Findings

volume is the measured area for brick and panels including mortar bonds which multiply by
the thickness of the walls.

3.00%
2.68%

2.50%

2.00%
1.68%

1.50% 1.38% ACOTEC


Brick
1.07% 1.07%
1.00%
0.76%

0.49%
0.50%

0.12% 0.12% 0.06%


0.00%
Delivery Waste Transit Waste Cutting Waste Fixing Waste Residue Waste

Figure : Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Project A)

7.00%
5.97%
6.00%

5.00%

4.00%
3.47%
ACOTEC
3.00% Brick

2.00%

1.00%

0.00%
Overall Wastage

Figure : Overall Wastage of Each Method (Project B)


Table-12 presents the labour involvement and the coverage of area during the observation of
project B under each method. According to the Table-12 with the total 28 labour days to
cover 157.89 m2 were covered using ACOTEC panels which approximately 6 m2/ (Labour
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Chapter Four Research
Findings

Day). But it took 44 labour days to cover 66.14 m2 with brickwork (including the both side
plaster work) which is less than 2 m2/ (Labour Day). Hence according to the figures of project
B ACOTEC panel installation is approximately 3 times faster than the brick wall partitioning
work.

Table : Labour Involvement & Coverage of Work (Project B)

Skilled Unskilled Coverage Actual


Nr of
Method Date labours labours Area Coverage
Panels
(Nr) (Nr) (m2) (m2)
1/11/2017 1.00 3.00 16.00 23.79 22.86
1/12/2017 1.00 3.00 15.00 22.30 21.66
1/13/2017 1.00 3.00 15.00 22.30 21.43
1/14/2017 1.00 3.00 16.00 23.79 23.13
Acotec Panel
1/15/2017 1.00 3.00 17.00 25.28 24.05
1/16/2017 1.00 3.00 16.00 23.79 23.15
1/17/2017 1.00 3.00 15.00 22.30 21.61
Total 7.00 21.00 110.00 163.55 157.89
 
Skilled Unskilled Coverage Actual
Nr of
Method Date labours labours Area Coverage
Bricks
(Nr) (Nr) (m2) (m2)
1/2/2017 2.00 2.00 680.00 13.08 12.04
Brickwork
1/3/2017 2.00 2.00 780.00 15.00 14.30
(Brick
Laying) 1/4/2017 3.00 3.00 1160.00 22.31 21.20
1/5/2017 3.00 3.00 1020.00 19.62 18.60
1/16/2017 4.00 2.00 N/A N/A N/A

Brickwork 1/17/2017 4.00 2.00 N/A N/A N/A


(Plastering 1/18/2017 4.00 2.00 N/A N/A N/A
Both Sides)
1/19/2017 4.00 2.00 N/A N/A N/A
Total 26.00 18.00 N/A N/A 66.14

According to the figures of Table-12, if the labours used for brickwork could be used for
ACOTEC panel work, they could have completed approx.264m 2 which is a massive work
done.

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2
Labour cost of each method is representing by the Table-13. To cover up 157.89m of
internal wall area, it took only Rs.39,900.00/- for ACOTEC panel while it took 70,200.00/- to
construction of brick wall partitioning cost including the both side plaster work. The Labour
cost of brick wall construction is approximately 420% is greater the installation of ACOTEC
panel as per the observation records of project B.

Figure-7 represents the analysis of work done over labour involvement referred to the Table-
12 for the easy understanding. Cumulative work done of both systems is shown clearly. As it
is shown, in brickwork series, work done will be same even though there was labour
involvement. The reason is plastering work. Brick walls need to be plastered but ACOTEC
walls do not required a plaster work.

70.00

60.00

50.00
Area Covered (m2)

40.00

30.00 ACOTEC
Brick

20.00

10.00

0.00
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00 45.00 50.00
Number of Labour Days

Figure : Construction Speed of Brick Wall and ACOTEC Wall (Project B)

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Table : Labour Cost of ACOTEC panel and Brick Wall (Project - B)

Item
Description Unit Qty Rate Amount
Nr
Labour cost of installing ACOTEC
1.00        
panels
1,800.0 12,600.0
1.01
Skilled Labour day 7.00 0 0
1,300.0 27,300.0
1.02
Unskilled Labour day 21.00 0 0
Total Labour cost of installing ACITEC 39,900.0
 
panels       0
157.8
 
Total Coverage of work m2     9
252.7
 
Rate per 1m2 Rs.     1
           
           
2.00 Labour cost of brick wall construction        
  Brick Laying        
1,800.0 18,000.0
2.01
Skilled Labour day 10.00 0 0
1,300.0 13,000.0
2.02
Unskilled Labour day 10.00 0 0
31,000.0
 
Total for brick laying       0
           
  Plastering        
1,800.0 28,800.0
2.03
Skilled Labour day 16.00 0 0
1,300.0 10,400.0
2.04
Unskilled Labour day 8.00 0 0
39,200.0
 
Total for Plastering both sides       0
           

  Total cost of brick wall construction 70,200.0


with plastering both sides of the walls       0
66.1
 
Total Coverage of work m2     4
           
1,061.3
 
Rate per 1m2 Rs.     8
           

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4.3.0 Overall Results


This section illuminates the overall results that have been perceived within the observation of
the partial construction of the residential projects described. Wastage and labour involvement
with respect to the coverage area of work are highlighted for both brickwork and ACOTEC
panel installation work.

4.3.1.0 Overall Results of Wastage


Figure-9 presents wastage levels occurred during brickwork and ACOTEC panel installation
work. For the estimation of wastage level, measured consequences of two undertakings have
been considered since there was a huge consistency and replication among these two tasks.
The general outcome demonstrated the level of waste under the establishment of brickwork
and ACOTEC boards. Brickwork construction with 6.65% was approximately 200% times of
waste produced by ACOTEC panel installation work with 3.27%. Figure 4 clearly shows the
difference of waste levels originated under two systems. The levels of ACOTEC panel waste
showed some consistency while considerable deviation for brick wall construction with poor
attitudes of labours and lack of quality of materials.

3.00%

2.50% 2.46%

2.00% 1.90%

1.51%
1.50%
1.18% 1.22%
ACOTEC
1.00% 0.84% Brick

0.50% 0.45%

0.13% 0.17%
0.07%
0.00%
te te te te te
as as as as as
W W W W W
y it ng g ue
er ns in is d
le iv Tr
a
Cu
tti Fix
D Re

Figure : Different Types of Waste Generated from ACOTEC and Brick Wall Construction
(Overall)

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Chapter Four Research
Findings

7.00% 6.65%

6.00%

5.00%

4.00%
3.27% Brick
ACOTEC
3.00%

2.00%

1.00%

0.00%
Partitioning System

Figure : Avg. Wastage

1.20%
1.09%

1.00%

0.81%
0.80%

0.60%

ACOTEC
0.40%
Plastering

0.20%

0.00% 0.00% 0.00%


0.00%
te te te te te
as as as as as
W W W W W
er
y
nsit ng ing ue
le iv a tti Fix is d
D Tr Cu
Re

Figure : Different Types of Waste Generated from Plastering (Overall)

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Special Note:-

There was wastage for ACOTEC panels which cannot be avoided due to cutting required to
rest the lintel where the doors, windows and opening are located. It was a common problem
in ACOTEC panels.

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