FRIM Technical Information Handbook No.

CONSTRUCTION MANUAL
OF PREFABRICATED TIMBER HOUSE
by

Mohd Shukari Midon

Chu Vue Pun
Hilmi Md Tahir
Nor Azian Mohd Kasby

ITTO
--------_._---------
 FRIM Technical Information Handbook No. 5

CONSTRUCTION MANUAL
OF PREFABRICATED TIMBER HOUSE

by

Mohd Shukari Midon

Chu Vue Pun
Hilmi Md Tahir
Nor Azian Mohd Kasby

Manual produced under the project

"Research on the Utilization of Tropical Timber in Construction".
An International Tropical Timber Organization (ITTO) funded project
carried out at the Forest Research Institute Malaysia (FRIM).

ITTO
Forest Research Institute Malaysia International Tropical Timber
(FRIM) Organisation

1996
© Forest Research Institute Malaysia (FRIM)
1996

Perpustakaan Negara Malaysia Cataloguing-in-Publication Data

Construction manual of prefabricated timber house I by Mohd.

Shukari Midon ... [et al.].
(FRIM technical information handbook, ISSN 0127-9793; no. 5)
ISBN 983-9592-55-6
1. Wooden-frame houses - Design and construction - Handbooks,
manuals, etc. 2. Prefabricated houses - Design and construction -
Handbooks, manuals, etc. I. Mohd. Shukari Midon. 11. Institut
Penyelidikan Perhutanan Malaysia. Ill. Series.
721.0448

Editorial: Norani Ahmad & Nik Zanariah Nik Mahmood

Typesetter: Zuriati Ahmadin

CONTENTS

PREFACE

ACKNOWLEDGEMENTS

1 INTRODUCTION, 1

2 FABRICATION SYSTEM, 2
Pre-cut system, 1
Modular panel system, 1
Large size panel system, 2
Volume element system, 4

3 DESIGN OF THE HOUSE,S

4 BASIC PRINCIPLES, 8
Sequence of construction, 11

5 GENERAL REQUIREMENTS AND SPECIFICATION OF MATERIAL, 13

General requirement, 13
Specification of material, 14

6 DETAILS OF CONSTRUCTION, 17
Site access, 17
Preparation of site, 17
Setting out, 18
Footings, 21
Platform, 21
Wall panels, 25
Kitchen, 28
Roof trusses, 30
Doors and windows, 34
Railings and stairs, 34
Ceiling, 35
Services, 37
Finishing touches, 38
7 MAINTENANCE AND REPAIR, 39
Raised platform, 39
Exterior walls, 39
Interior, 40
Roof,40

REFERENCES, 41

APPENDIX
Appendix I, Detailed Technical Drawings of the Whole House
 PREFACE

This manual is the end product of the FRIM/ITTO project on "Research on

Utilization of Tropical Timber in Construction". The project which was cqrried
out in FRIM was funded by ITTO together with some financial support from
PRIM. The aim of the project was to come up with a manual to illustrate the
construction of a prefabricated 10w-cost' timber house.
This manual is able to assist those who wish to build prefabricated timber
houses either mass-prod uced in a factory or as single uni ts. The type of house
given in this manual is of the timber-framed type, based on the platform
method. This manual attempts to show builders the good practice of producing
houses so that these houses can perform in a manner as expected of a good
timber house. The fundamental principles of timber-framed housing are also
explained. These general principles are also applicable to other timber frame
methods.
The house as described in this manual is only a typical factory made timber-
framed house. Other arrangements of the house as regards to layout, height,
size, etc. are possible and can be built using similar procedure and guidelines
as given in this manual.
Beside describing the procedure in building the house, this manual also has
a chapter on the maintenance of the house after it has been built and is being
occupied. A brief specification of the timbers and the types of materials used
in the construction of the house are also given.
 ACKNOWLEDGEMENTS

The publication of this manual is made possible with the financial support
and assistance from the International Tropical Timber Organization (ITTO)
through its funding for the project "Research on the Utilization of Tropical
Timber in Construction" which was carried out in the Forest Research
Institute Malaysia (FRIM).
We wish to record our thanks to Dr. Salleh Mohd. Nor. the former
Director General, and Dr. Abdul Razak Mohd. Ali, the present ,Director General
of FRIM for their encouragement, and the supporting staff for their
assistance throughout this project.
 Chapter 1

INTRODUCTION

There are at present in Malaysia a number of factories making prefabricated

timber houses using their own proprietary system of construction. The prefab-
ricated house as proposed here is another method of construction where the
parts of the house may be assembled in the factory or at the site in a do-it-
yourself manner. Since there are very few guides available on the construction
of timber houses, it is believed that a manual of this type illustrating such
construction would be useful to builders of timber houses.
The aim of this manual is to recommend a system of construction not as a
close proprietary system but as a general method for all who are interested in
the use of timber.
The system of prefabrication proposed in this manual is the result of
research carried out in FRIM on the structural strength of timber, timber joints,
wall panels, roof trusses and the different components that made up the whole
house. The system proposed here is the Modular Panel System.
The house can be built individually or mass-produced in a factory since they
are of the prefabricated system. The step by step procedure in building the
house as described herein is straight forward and easy to follow. There are
many illustrations or sketches in this manual and this would further help a
builder to comprehend what is described in the text. Not all the detailed
dimensions of the various components are given in the text of this manual, but
attempts are made to show the procedure and the sequence of construction.
Detailed dimensions of the various components are given in the drawings of the
house, in the Appendix.
Although the house is primarily designed for use in Malaysia, it would
also be suitable for the building to be constructed in regions with similar
climates, except in places which have very strong winds or hurricanes.
The arrangement of the house such as the partition of the rooms, hall, or
other internal partitions can be altered to suit individual preferences without
affecting the structural strength of the house as a whole, since these partitions
are designed as non-load bearing walls.
 Chapter 2

FABRICATION SYSTEM

There are a number of prefabrication systems in building a timber house. The

following are some of them.

Pre-cut system

The pre-cut system is the oldest system of prefabrication. Pieces of timber

are processed, cut to the required lengths, notched or drilled at the factory. The
pieces are then marked and transported to the site for assembly. Transportation
of the pre-cut timber is simple because they can be bundled into units and
delivered to the building site. Compared to the conventional method of cutting
timber in falling lengths at the site, this system is more accurate in its measure-
ment and material wastage is minimised. .

Modular panel system

Under the modular panel system, building components are constructed in

the factory by two or three men without the use of cranes or other lifting
devices. Wall panels are in uniform sizes using a module (M) as a unit of
measurement. The normal unit 'M' is 1.22 m (4 ft.) in length to tally with the
size of most cladding materials in Malaysia such as plywood, hardboard,
chipboard and cement board. The mod ular panel system is the system adopted
in this manual (see Figure 1).
 r=::=- Roof truss

Ceiling panel

joist

Figure 1. Modular panel system

Large size panel system

The large size panel system as shown in Figure 2, is suitable for use when
constructing a large number of small houses at the same time. Large panels up
to 10 to 12 m equalled to the length of adwelling can be assembled in the
factory and delivered to the building site for erection. The use of large size
panels reduces the problem of joining together the small prefabricated panels
satisfactorily at the building site. However this advantage is offset by the
increased in transport and handling costs and the necessity of using cranes in
lifting the large panels.
 ___ Roof truss

Figure 2. Large size panel system

Volume element system

In the volume element system of prefabricated housing, dwellings are
completely finished at the factory. This system permits a home buyer to see
exactly what his house will look like before it is built. This method of
construction is very much faster than the other methods as far as site erection
is concerned, but it requires the use of trailers for transportation and cranes for
erection (see Figure 3).

~=------ Foundolion beams

Figure 3. Volume element system

A
 Chapter 3

DESIGN OF THE HOUSE

The traditional method of house construction in Malaysia is of the post and

beam structural form in which beams spaced widely apart (between 2 and 4 m
in domestic buildings) are supported on individual columns or posts to form a
skeletal structure. The non-load bearing infill panels will form the wall and
window units between the columns.
The house proposed in this manual is the timber-framed or wood-framed
house and falls within the category of modular panel system as mentioned
previously. The method of timber-framed house construction is traditional in
North America, Scandinavia and some other parts of the world but is compara-
tively new in this country.
Basically there are two methods of building a timber-framed house, the
balloon frame and the platform frame method. The balloon frame method has
studs running the full height of the building and the intermediate floor joists are
side-fixed to the studs and supported from them. The system is only suitable
for either two or four storey buildings. In the more common platform frame
method the shell is built one storey at a time using storey height wall panels to
support the intermediate floors, which are then used as a construction platform
to erect the next storey or the roof above. The platform frame method is used
in this manual. These two framing methods are shown in Figures 4 and 5.
In timber-framed housing, partitions or wall panels are assembled by
having the top and bottom horizontal plates spaced at a distance apart to suit
the designed height of the building which in this case is 2.75 mm (9 ft.) high.
Vertical studs at generally 0.16 m centres are then nailed to the top and bottom
plates. Where necessary noggings are added in to strengthen the edges of the
intended sheathings. Sheets are then fixed to the framework either on one side
only or on both sides. For simplicity all the framework is assembled with butt
joints and fixed with nails. Figure 6 shows such a wall panel which is normally
prefabricated at the factory. For ease of man-handling, the pre-assembled wall
panels are made to a length not more than 3000 mm long. The wall panels are
then erected over the prepared platform and the roof is put over it to complete
the building.
 Stud full height
01 building

Figure 4. Balloon frame method

The main advantages of the timber-framed system of construction are:

(1) Transportation of pre-assembled panels is simple;
(2) Less labour is required on site, even when the panels are made up on
site. If the panels are assembled at the factory, considerable saving in
labour are possible;
(3) The pre-assembled wall panels can be erected manually by two or
three men without the use or cranes;
(4) More speedy erection. It is possible to put up the whole timber-
framed wall panels of a house within two to three days. Once the roof
is covered, other works such as plumbing and electrical services can
be started inside under assured dryness;
(5) Houses can be finished at low cost to a high standard of thermal
insulation,
(6) Flexibility in architectural design, modification and extension is
possible.
Figure 5. Platform frame method

.1
I

\t".".
Figure 6. Typical prefab wall panel
 Chapter 4

BASIC PRINCIPLES

The dimensioning of the house is based on a modular system which means the
best use is made of materials, especially sheet materials and also the house can
easily be extended at a later stage. Most sheet materials obtainable locally are
of size 1220 x 2240 mm, therefore the planning of the house is based on the use
of dimensions which are multiples of 610 mm. Hence a grid of 610 mm is used
in the plan layout as well as positioning in fixing of the partitions, roofs, joists,
etc. These and an alternative future extension are shown in Figure 7. In the
modular panel system, architects can design a wide variety of houses with
many different floor plans using prefabricated panels.

extensIOn
r.~
Proposed
4270
r Grid tines
610 mm crs.

I w t:
! I-- c -
IKi~. S
I

I I I I
II
I Is R2
I

I I I
i I ! I ILVD I SR 31
I I I
I
BR1 i I I
V I I
I I
I I

I I I 1 1T I
7320 30<;0

Proposed house
With extension

Figure 7. Plan of building on grid lines

 Unlike the post and beam type of construction where the load is supported
by the post and beam, the timber-framed house has the wall panels supporting
the load which means the wall panels are made load bearing.
In the arrangement of different components of the house, it is desirable that
roof trusses, studs in wall panels and floor joists are kept in line (see Figure 8)
for efficient transferring of load from the roof to the ground via these members.
In this proposed house, the spacing of the trussed rafter roofs is at 1220 mm
centres while those of studs and floor joists are at 610 mm centres.

Roof truss @ 1220 ers

t
-Roof truss

r-;-H ead binder

Top plate

.6=
-Veri ieal stud

Nog
Lint el

Crip pie stud

Door

Bottom plate
11
/
,- Base plate

+ M [Xl M l~ lXl M-t- Floor board

Floor joist
/ f
l- Bearer
Joists @ 610 ers

Figure 8. Vertical alignment of roof, stud and joist

 Wall panels can be of load bearing or non-load bearing walls type. Load
bearing walls are designed to support the floor and the roof above them. Non-
load bearing walls do not support any load above them and they function as
partitions. They are therefore made shorter than the load bearing walls in the
same storey so that the roof or the floor joist above them does not rest on these
walls as shown in Figure 9.

Hon -load bearing

~bearing wall

Figure 9. Clearance for non-load bearing wall

If there is an opening in the wall panels such as for door or window, a lintel
is required to span the opening. The ends of lintels are supported on extra studs
known as cripple studs which are fixed at each side of the door or window
opening as in Figure 8. For small openings, lintels are not necessary; they can
be fitted between studs and are simply framed up.
The following sizes and tolerances must be observed in making wall panels:
(1) Depth oftimber studs must be the same throughout, so thatthe width
of the finished panel with sheathings is the same. For example, if the
stud is specified as 47 by 97 mm then the latter dimension must be
accurate or regularised.
(2) A vertical gap of between 1 to 3 mm should be provided between
plywood sheathings to allow for their expansion. The gap is then
covered up with beading.
(3) The finished length of each completed prefabricated panel is to be 1
to 3 mm less than the finished size as stated in drawing.
The house may be built as a separate detached unit or linked to each other
by a separating wall as shown in Figure 10.
 id lines
T~r
-pr-1.-/
v
- J05 mm

V // Separatin wall

V
House 1 V // House 1

V /
/
f' V/ / / / / / /V Vf/
/

,305 \,
, (mlnJ '

Figure 10. Plan of separating walls

Sequence of construction

The proposed house is shown in plan view in Figure 7 and in perspective view
in Figure 11. The main building at frontal end is on a raised platform which is
700 mm above the ground and the kitchen at the back is on ground level. The
total built-up area is 50 m 2 and the height of the building from floor to ceiling
is a comfortable 2745 mm (9 ft.). The house can be enlarged in the future in a
direction as shown in Figure 7.

Figure 11. Perspective view of house

 In the sequence of construction the ground is first prepared by laying
concrete footings. Posts are erected over the footing. Bearers are attached
across the posts with bolts. Floor joists with stiffening across pieces are laid over
the bearers. Floor boards with tongue and groove are conceal-nailed to the joists
and the platform is now ready for the next stage of construction.
Over the platform, pre-assembled wall panels are put up. During this time
work can also start simultaneously in the kitchen which is on ground level and
which is not connected to the platform at this stage. When the panels are erected
over the platform as well as over the kitchen, head binders or wall plates will
then bind the top of the panels together; and they also act as support for roof
trusses. The panels are also fixed firmly together sideways with nailed iron
plates or angles, which are then concealed with beading.
On top of the wall plates, prefabricated trussed rafter roofs are fixed. The
rafters are braced diagonally and purlins are nailed over them. When roofing
sheets have been laid, the dwelling is protected from rain and shine. Doors and
windows can now be installed. All other subsidiary works such as plumbing,
electrical wiring and sanitation can be commenced.
The house may now be painted and is ready for occupation.
 Chapter 5

GENERAL REQUIREMENTS AND

SPECIFICATION OF MATERIAL

General requirements

The general requirements for materials for the house are as follows:

Timber

Timber group: Strength Group B as given in the Malaysian Standard

Code of Practice M.S.544 :1978 [SIRIM(2)].

Timber grades: Standard structural grade in accordance with Part Ill,

Section J MGR(3).

Timber size: As given in drawing. Exposed surfaces shall be planed,

unexposed surfaces sawn unless regularised, such as
studs size of 47 x 97 mm where the dimension of 97 mm
is fixed.

Moisture content: At time of installation, MIC of floor boards shall not

exceed 18% and MIC of other timber shall not exceed
22%.

Treatment: Pressure impregmented with CCA to a dry salt retention

of 5.6 kg m-3 and the depth of penetration of CCA shall
be at least 12 mm.

PlywoQd

Plywood should be purchased from a reputable mill. It should be either of

the water boil proof (WBP) type or of the moisture resistant (MR) type in the
respective position as stated in the plan.
Cement-bonded particleboard

Cement-bonded particleboard for kitchen use should be obtained from a

reliable agent of the cemboard manufacturing factory. Fixing of cement-
bonded particleboard shall be in accordance with manufacturer's instructions.

Others

All other materials should be obtained and used in a manner consistent with
good construction practice.

Specification of materials

The specification and quantities.of materials as given in Table 1 are only as

a guide. The detailed dimensions can be obtained from the technical drawings,
in Appendix 1.

Table 1. Specification and quantities of materials

Item No Part Material Size (mm) Remarks

(A) Platform

Al Post Timber 120 x 120 Top or conc. footing

A2 Bearer 60 x 197 B/Sofpost
A3 Bearer splice 30x 194 Lengthen splice
A4 Joist 47x 145 Top of bearer
A5 Joist stiffener
(I) SOx SO At end of joist
A6 (II) SOx 75 At mid joist
A7 Floorboard 22 x 145 T&G
A8 Header joist 20x 194 Oose joist gap
A9 Base plate 47x 112 Thicker panel
AI0 Bolts & nuts M.5. 12.7 dia. Joint fastener
All V-strap 6mm thick To fix post
A12 Plate 6mm thick Bearer for post
A13 Round bar 12.7 dia. Reinforcement
A14 Cone. footing Concrete 1:2:4 mix Footing for post
A15 Hardcore Stone 25 mm size Forconc.

(B) Kitchen floor

Bl Floor Concrete 100 mm thick Whole floor

B2 Curb 50 x 115 Thicker panel
SOx 88 Thinner panel
B3 Hardcore Stone 25 mm size For conc.
(C) Wall panels

Cl Studs (I) Timber 47x 97 Thicker panel

C2 (11) 47x 72 Thinner"
C3 Untel (I) 97x 145 Thicker"
C4 (11) 72 x 145 Thinner "
CS Sheathing (I) Plywood 9mmWBP Outside surface
C6 (11) 6mmMR Inside"
C7 Sheathing (I) Cemboard 10mm Kit. O/S
C8 (II) 8mm Kit. liS
C9 Beading (I) Plywood 9mm In strips
CI0 (II) Cemboard 8mm
Cll Pyrda nail plate Product 63x 89 Connection, flat
C12 angle 11 44x 44x93 corner
C13 Plate w /holes M.5. 80x 80 Connection, Cemb.
C14 Angle plate w /h 48 x48 x80 Con. Cem. corner
C15 Dowel 12.7 dia. Embedded in curb

(D) Head binder

Dl Platform (I) Timber 47x 112 Bind thick panel

D2 (11) 22 x 84 " thin
D3 Kitchen (I) 47x 115 Bind thick panel
D4 (II) 22 x 88 " thin

(E) Roofing

El Rafter, tie, web Timber 35 x 72 Truss assembly

E2 Brace 22 x 97 Brace truss
E3 Nogging 38x 50 For ceilling board
E4 Gusset plate Plywood 9mmWBP B/S of truss joint
E5 Gable end " to close end
E6 Ceiling 4mm MR 2' x 8' zigzag
E7 Purlin Timber 35x72 Top of truss
E8 Fascia board 20x 145 All round roof
E9 Roofmg sheet Fibrecem 1830&2440 2 sizes
ElO Ridge piece Product At peak

(F) Door and window

Fl Flush door (I) Ply/timber 0/ A 840 x 2100 Main entrance

F2 "(11) 770 x 2100 Room / kitchen
F3 "(III) 770 x 2100 Bath /WC
F4 Window (I) Adj/fixed louv." 1055 x 1587 7 off, platform
F5 (II) 414x 1587 1 off,
F6 Window only Adj.louv. 1055 x 1213 loff,
F7 Fixed louv. (I) Glass 403 x 610 loff,
F8 (11) 440x 610 1 off,
F9 (Ill) 700x 610 1 off,
(G) Water Tank

Gl Water tank Product 7SOx 1220 x Top of bath

540 high
G2 Beam Timber 4 /47 x 97 Tank support
G3 Seating Plydood 9mmWBP Top of beam

(H) Stairs (2 off)

HI Stringer Timber 60 x 219 Entrance & kit.

H2 Tread 47x 2SO 2/3 treads
H3 Support strip SOx SO Attd. to string
H4 Angle iron M.5. 63x 63 x 200 Landing attach

(I) Railing

11 Railing Timber 47x 97 Frame for mesh

12 Balustrade 20x 20 To rail and floor

(J) Wire mesh in Kitchen

Jl Framework Timber 47x 97 Frame for mesh

J2 Wire mesh Product SOx SO crs. Oose opening

1£
 Chapter 6

DETAILS OF CONSTRUCTION

Site access

Before construction begins, access to the site must be looked into, especially if
the house is to be built in a remote area. If necessary an access road suitable for
vehicles has to be constructed to transport construction materials to the site.
Al though most of the component parts of the building are pre-assembled at
the factory, electric power and water supply are still required for many tasks
during the building process. Electric supply may be obtained from the supply
mains or obtained from a generator. Water may be obtained from the water
mains, well, river or transported to the site.
At the plot, besides the area required for the proposed house, space for the
storage of prefabricated components and other building materials must be
allocated away from building sites.

Preparation of site

The site of the house must be prepared first before construction work begins.
The soil is examined to see whether it is suitable for the building. Since the
proposed house is constructed of timber and is therefore light, most normal
soils would be suitable for its erection. If the place is known to be infested with
termi tes, an anti-termi te treatment is recommended for the soil before construc-
tion begins.
The site should be cleared of all unwanted vegetation. During the process
of grading, roots and other cellulosic materials should be removed, from the
building lot. Care must be taken to obtain adequate drainage of the area and in
particular of the building site. The frontal of the house may be built on level
ground or on a gentle slope as this portion is of the raised platform type and
hence the platform can be made level by adjusting the footing level or the length
of the post (see Figure 12). The height of the floor must be at least 700 mm above
the ground for effective ventilation. The site for the kitchen at the rear should
be made level by cu tting or filling earth with proper ramming to ensure the
prepared surface is firm.

17
 (il Footing adjustment

_ Oatu~ ~i.!1i (!.!at-fo~ '- _ _ _

Post
G.L

(ii) Post adjustment

Figure 12. Platform on sloping ground

Setting out

When the site is prepared, the next step is to locate the house on the plot. The
house should not be built too close to the boundary to allow rooms for one to
move around the house with ease. Also if there is a house in the neighbouring
plot, the empty space acts as firebreak. In Malaysia the minimum spacing is
specified in the Uniform Building By-laws, 1984 or the latest edition. If the plot
is large enough building is located near one end of the plot to give allowance for
future extension (see Figure 13).

lR
 Proposed building

Future
extension /
/
/
/

Figure 13. Position of building in plot

When setting out the position of the platform, first mark on the plot the
approximate outline of the whole platform by driving in temporary pegs at the
four corners of the house where the footings are to be built.
From the markings on the ground, set outthe corners of the house by putting
in batter boards. There are two batter boards at each corner, making it eight for
the four corners. The batter boards consists of two vertical stakes 50 mm x 100
mm x approximately 1 m long driven into the ground. These stakes are fixed
at a minimum distance of 1 m beyond the lines of corner foundation footings to
avoid being disturbed during excavation (see Figure 14). A horizontal board of
25 x 150 mm is then nailed to the vertical stakes. The tops of all horizontal batter
boards are made the same level. This can be achieved by checking with a
surveyor's level or by using a transparent hose filled with water as shown in
Figure 15. The highest corner of the house is chosen as the datum batter board
where the levels of all other batter boards should follow.
When the batter boards are in position, strings are then stretched taut
between the boards. To indicate the positions of the strings in the batter board,
a nail is driven or a saw kerf is made on the board so that the string may be
replaced if disturbed. Two adjoining sides of the building are first set using two
steel tapes. To check the squareness of the two sides, a third tape is used to
measure the diagonal. The lengths of the two sides are 7230 mm and 5400 mm.
The length of the diagonal is therefore equal to:

Diagonal -J(723()2 + 540()2) == 9096

If the above length is too long, the squareness of the corners can also be
achieved by using the common rule of "3-4-5" for a perfect 900 corner as
shown in Figure 16. The sketch also shows the position of the first corner by
using a plumb bob and driving a nail into a stake underneath it. With the above
procedure, three corners of the house are fixed. The fourth corneris established
in a similar way. Check the diagonals again to make sure all corners are square.
Intermediate points of the footings are next marked using a steel tape and
plumb bob. The measurements should always start from the corners and move
along the string. The ini tial settings of the stakes may be corrected now if they
are not accurate. The positions of all 12 footings are now set.

Oiagonals equal

Cenlre line of foolings

Figure 14. Fixing outline of house

Board to be
fixed here
Oatum catter boara

Transparent plastIC i(

f ~ hose with waterol,

~~3;,'(~
~I

Figure 15. Leveling batter board

 f',rst cor ner point
on ground

Figure 16. Fixing one corner

Footings

The strings can now be removed bu t the ba tter boards should be left in position
undisturbed, for further alignment and levelling.
Excavate soil for the 12 footings at the positions marked on the ground. The
size of each hole is 600 mm square and 400 mm deep. When the holes are ready,
hardcore is placed into the holes and rammed properly up to 150 mm thick. A
level of sand is put on top of the hardcore.
Construct framework to hold the concrete. The minimum depth of concrete
footing is 300 mm but may be of greater depth depending on the contour of the
land If it is decided that the top surfaces of all concrete footings are of the same
level. Top of concrete footing should be a minimum of 50 mm above the ground
level. The other alternative is to vary the lengths of the posts over the footings
in which case the footing surfaces need not be of the same level. Before concrete
is poured, reinforcement consistingof12 mm diameter Mild Steel (MS) bars are
placed near the bottom of each footing and MS V-strap for the posts are put at
the top of the footing. The V-straps must be properly aligned and levelled by
using strings between batter boards and plumb bobs as shown in Figure 12(0.
Concrete can now be mixed. The proportion of the mix is 1 part cement, 2
to 3 parts sand depending on its wetness and 4 parts stone. Mixing of concrete
is preferably done using concrete mixer. If mixer is not available, mixing can be
performed manually but it must be done thoroughly until the whole mix is
uniform. The mixed concrete is then poured into the prepared framework and

'),
is then rodded or vibrated to achieve a dense concrete making sure the fixed
reinforcement is not being disturbed.

Platform

When the concrete footings are made, the next step is to fix the posts over
the footings. First put in MS bearing plates 120 x 120 x 6 mm thick within the
V-strap and then put in the posts, each measuring 120 x 120 x 499 mm high. Fix
the bottom of each post to the V-strap with 2 bolts through holes previously
drilled (Figure 17).

~---Bearer 1/.7 x 19,

Conc. looting - -..........

Plate 110 x tl0 x G

Figure 17. Joining details of post and bearer

Bearers can now be attached to the top of posts, one on each side with 4 bolts
running through the 2 bearers and post. Washers are required for all bolt heads
and nuts if they bear directly on the timber surface. The bearers are lengthened
by splice jpints at a place between the posts as shown in Figure 17. While fixing
the bearers, care should be taken to ensure the posts are truly vertical, the top
of all bearers are horiwntal and of the same level.
Floor joists are next placed on top of the bearers. They are fixed to the bearers
by slant nailing using 75 mm nails, one on each side of the joist as shown in
Figure 18. To stiffen the joists and to prevent them from tilting, stiffening cross

?')
pieces 50 x 50 mm are placed at each end and 50 x 75 mm at the centre. To
accommodate the cross pieces, notches are cut at the top ends of the joists.
Figure 19 shows the joists being fixed in posi tion with the stiffening cross pieces
embedded in the joists.
Floor boards in the form of strip flooring 30 x 145 mm with tongue and
groove are next laid over the joists. Fit groove of one board to tongue of the
matching board snugly and blind-nail through the tongue to the joist below as
shown in Figure 20. A board or header joist 20 x 194 mm is fixed to the ends of
the joist with its top level with the floor boards as shown in Figure 21. This board
will conceal the empty spaces between the joists.

_Joist

Bearer

Figure 18. Slant nailing of joist to bearer

 earer

End notch ior

Figure 19. Attachment of cross piece to joist

Groove ----

Tongue

Figure 20. Concealed nailing of floor board

 floor board r &G

floor iOISI

Cross piece
50 x 50

Header 10iSl 10 x 19. J

Figure 21. Floor boards on joist

The whole platform is now complete. At this stage the construction of the
rear portion of the kitchen can be started either separately or simultaneously
with the main building. The description of the kitchen's construction is given
later.

Wall panels

Wall panels can now be erected over the pIa tform. For speedy work panels are
pre-assembled at the factory and transported to the site before the completion
of the platform. The panels can of course be assembled at the site especially if
only one individual house is built. Panels assembled at the factory are usually
more accurate than those assembled at site.
lf assembled at site, extensive labour can be saved by having all major pieces
such as studs and sheathings pre-cut to the correct sizes in the factory before
delivery. The assemblage of panels can be done on level surface such as a
concrete slab or on makeshift trestles.
Base plates or sill plates, where wall panels are erected, can now be fixed
over the platform. The sizes of the plates are 47 x 112 mm for the exterior walls
and 47 x 84 mm for the interior walls to match the widths of wall panels. The
position of these plates are as shown in Figure 22. After making sure that the
posi tions and the squareness of the corners are correct, nail the plates to the floor
boards using 76 mm nails at 300 mm centres in a zigzag manner.
 4077 1576

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Figure 22. Base plates and the type of joints used

The pre-assembled wall panels can now be installed. The first panel to be
installed is the corner one which is panel No. 1 in the drawing. Nail the bottom
of the panel by skew-nailing to the base plate. To prevent it from tipping over
and to maintain its upright position, it must be propped up by using temporary
diagonal bracing as illustrated in Figure 23. These temporary bracing can only
be removed when the panels are permanently fixed in position. Subsequent
panels are similarly erected. There are altogether 21 panels over the whole
platform and 6 panels over the kitchen. Figure 23 shows three panels had been
put up over the platform area and are arbitrarily numbered 1, 5 and 6 as in
drawing.
The panels over the platform are 2745 mm (9 ft.) high and the longest length
is 2550 mm so that they can be man-handled without the use of cranes. It is
suggested that to ease lifting the panels which are sheathed both sides, four
handles are temporarily fixed at about 1000 mm high near the ends of each
complete panel. The handles are solely used for the purpose of lifting the panels
during construction and can be removed as soon as the panels are in position.
 Figure 23. Erection of panels

Wall plates or head binders are now fixed over the top of the wall panels.
Wall plate sizes of 47 x 112 mm are fixed over the thicker exterior walls while
the 22 x 84 mm pieces are fixed over the thinner interior walls. As mentioned
previously the thinner plates, 22 mm as against 47 mm, are used so that the roof
trusses do not rest on them because these interior walls are not designed as load
bearing walls. The fixing of wall plates to panels is done by nailing 76 mm nails
at 300 mm centres in a zigzag manner as was done in nailing the base plates to
the floor boards.
For attaching the panels to base plates, use Pryda knuckle nail plates 2N10
(89 mm wide x 63 mm depth with 2 rows of 10 punched-out nails) or similar
type. These plates are fixed at 610 mm centres on the exterior side of the panels
while the interior side is fixed with 76 mm nails skew-nailed to the base plates.
These metal plates and nails are then covered with plywood skirting 9 mm thick
x 100 mm wide. For side attachment of the panels to each other, use 3 pieces of
the same type as that used for bottom attachment, i.e. Pryda 2NlO or similar,
spaced out evenly. As for corner connection between two walls at right angles,
use 3 pieces Pryda angle plates 3NA (44 mm wide x 44 x 95 mm depth) or similar
type, fixed to the interior angle. All these plates should be covered with
plywood beading. Figure 24 shows the connection details.
When the wall panels with head binders over them are erected, roof trusses
can be put over them. Prior to this, the kitchen walls should be erected first
because the extended roof trusses of the main building rest on the rear kitchen
wall.

Plywood beading
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Figure 24. Connection of panel

Kitchen
Prepare the area for the kitchen which measures approximately 3.1 m x 5.1 m
behind the main building. Excavate the ground to the required level. Put in
hardcore and ram properly up to 100 mm thick. Blind the top area with sand
and wet the top liberally with water before pouring concrete. The mixture of
the concrete is 1:2:4 and the thickness is 100 mm. Concrete strip footings
measuring 150 mm wide x 50 mm thick are additionally provided below the
concrete floor where the wall panels are situated.
On top of the floor, concrete curbs are used as base for the walls instead of
timber sole plates as used in the platform area, reason being the wet nature of
the kitchen. The curbs are 50 mm thick and 115 mm wide for the thicker walls
and 50 mm x 84 mm for the thinner walls and their positions are as shown in
Figure 25. Bolts 12 mm x 100 are vertically embedded in the concrete curbs for
the purpose of holding the wall panels in position. 38 mm section of the bolt
head side is inserted in the concrete and the remaining length with threads is
exposed. The spacing of the bolts is about two bolts per panel (see Figure 26).
The wall panels in the kitchen are sheathed both sides with cement-bonded
particleboard, 10 mm thick on the outside and 8 mm on the inside. In pre-
assembling, only one side of the panel is first covered (10 mm side). Elongated
holes are drilled in the bottom rail of the panel which should match the bolts
embedded in the concrete curb. The panel is then put over the concrete curb
through the bolts and tightened with a nut and washer. The other side of the
panel is then covered with 8 mm cement-bonded particleboard in situ. For ease
of fixing the 8 mm cement-bonded particleboard to the stud, it is suggested
that holes for nails are first predrilled on the cemboard before nailing.
Wall plates are placed on top of the wall panels. Side and corner attachments
between panels are done by nailing "Pryda plates" or equivalent types in a
manner similar to the attachments done for the plywood panels as described
previously.

Cone· curb 50 x 115

for wall panels.

floor 100 mm

5Irip foot ing

ZOO x 100

Figure 25. Kitchen floor

 ·'MAl L PANE L

COHC KER6

Figure 26. Anchoring of wall panel to concrete kerb

Roof truss

As in wall panels, trussed rafter roofs should preferably be pre-assembled at

the factory and transported to the site when they are required. The trusses can
either be assembled using nailed plywood gusset plates as shown in the plan or
using proprietary brand punched metal plates. If metal plates are used, the
trusses will have to be fabricated by the factory supplying such plates. In this
case the sizes of the plates required for each joint are calculated by the licensed
factory while the sizes of truss timber members remained the same as in the
drawing.
The first truss is erected at one end. When it is in the correct position, nail
the truss to the wall plate. The end truss is then temporarily braced to the
ground at two places using 50 x 100 mm timber as shown in Figure 27. This
bracing, although temporary must be firm because all other trusses are to be
fastened to this end truss. The second truss can now be erected. The truss is
initially put upside down with the two ends resting on opposite sides 0 fthewaIl
plates and the peak of the truss pointing downwards as can be seen in Figure
27 above. The truss is then tilted up vertically using a long pole with a "Y" end
as shown in Figure 28. When it is in the correct position nail bottom of truss to
wall plate and brace temporarily to first truss. The rest of the trusses can be
erected in a similar way. Figure 29 shows the attachment of trusses to wall
plates by skew nailing 4/100 mm nails for each attachment, two on each side of
the truss.

Temporary bracing

Figure 27. Erection of first truss

Figure 28. Erection of second truss

 rSPtlce joint
Skew naded to
·. . all plate

KItchen
area

Platform
area

/./'~,.--.
Head binder

Wall panel

Figure 29. Attachment of trussed rafter to wall plates

The two gable ends of the trusses on the platfonn area are closed by fixing 6 mm
plywood sheets to the required sizes. Ventilation inside the roof is through
holes drilled in the plywood sheets of these two gable ends.
At the kitchen end, four of the trusses are provided with extended rafters to
cover the kitchen roof. These extended portions of the rafters rest on the wall
plate of the kitchen panels. Two additional beams the same size as the rafters,
i.e. 35 x 72 mm are provided between each pair of trusses to strengthen the
kitchen roof.
Four workers can manually erect the trusses in position. One worker sits on
each wall to nail the trusses to the wall plates, another works at the centre of the
truss to fix the top of the truss and another for general works including lifting
of the trusses into position. If a crane is used work will be faster.
In order to prevent swaying caused by wind force, permanent bracing in
accordance with the drawing is provided. Horizontal bracings are fixed at right
angles to the trusses. Diagonal bracings are placed at an angle of 450 to the
trusses starting from the top portion of the gable end truss to the bottom portion
of the fourth truss as shown in Figure 30. When all permanent bracings are in
place, the temporary bracings may then be removed.
 ~OiagOnal brace 12 1 97

LHorizontal brace
21 x 97

Figure 30. Bracing for trussed rafters

The next stage of construction is to place purlins on top of the trusses.

Purlins are 35 x 72 mm in size and are skew-nailed to each rafter with two 76 mm
nails, one on each side ( see Figure 31). Fascia boards and barge boards are fixed
to the ends of rafters and purlins.
Roofing sheets can now be laid over the purlins. The sheets are of corrugated
asbestos-free fibre cement sheets. They are laid in accordance with the manu-
facturer's instructions. From this stage onwards, work can be carried out in the
dry interior of the building irrespective of the weather conditions.

- Raller 15 x 71

Skew nad b/s

Figure 31. Fixing purlins

Doors and windows

Openings for doors, windows and fixed louvers are provided for when making
wall panels. However, for the door openings, a full length bottom rail of the
panel is initially retained so as to prevent the frames from being twisted during
handling. When the panels are installed, this exposed portion of the bottom rail
is cut out together with the base plate at this place as shown in Figure 32. Doors
and windows are assembled in the factory and delivered to the site for
installation.
The doors are of three sizes: 700 mm wide for WC and bath, 770 mm wide
for the kitchen door and 840 mm wide for the main entrance door. The height
for all doors is 2100 mm high, measured from floor level. It is important that the
dimensions of the doors and windows match exactly the openings provided
for on the wall panels after they have been installed in place. All doors should
open inwards.
To make the doors, the framework is first assembled making sure the overall
dimensions are correct and the corners are squared. Plywood sheets are then
glued and nailed to the framework on both sides.
Frames for windows and louvres are made at site in the openings provided
for in the wall panels. Adjustable louvre aluminium frames with 8 leaves are
then fixed to the wooden window frame. Glazing in the form of glass sheets cut
to size are slid into the slots of the adjustable louvre. Glass sheets are also used
as fixes glass louvres on top of adjustable louvres.

Railings and stairs

In making railings, use rails 47 x 97 mm and vertical balustrades 20 x 20 mm in

size. The top of the rail is constructed at 1000 mm above the floor.
In making staircase, the spacings for rise and run of the stairs are 170 and 230
mm respectively. The treads are 47 x 250 mm resting both ends on ledgers 50
x 50 x 180 mm which are fixed to the stringers 60 x 219 mm. The stringers are
leaned against the floor joist at the top and fixed to the concrete landing with
angle iron plates at the bottom as illustrated in Figure 33.
 Shaded part is cut out
only alter erection·

Figure 32. Frame for door opening

Ceiling

Before ceiling sheets are installed, noggings 38 x 50 mm at 610 mm centres are

first fixed between the roof trusses as in Figure 34. Ceiling may be of plywood
6 mm or cement-bonded particleboard 6 mm thick. Ceiling is required only
for the main building and not the kitchen. The ceiling sheets are nailed to the
noggings and trussed rafters in a zigzag pattern.
 1
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Services

Various services such as plumbing, electrical and sewerage works, can be

installed in the building as soon as the roof is covered with roofing sheets. For
general wiring, drilled holes in wall frames and floor joists are used. The holes
measuring 25 mm diameter are drilled at the centre of the section. They should
be located at least 300 mm away from the ends of studs, joists and other
structural pieces, and from any other hole as shown in Figure 35.
Notches for piping and wiring can be made at the joists if the following
conditions are followed:
(1) All notches must be in top edge of joist,
(2) The location of the notches from the support end should be between
1/10 and 1/5 of the joist span, and
(3) Maximum depth of notch is equal to 21 mm for a 145 mm joist.
Instead of notches, holes can be drilled in joists for piping as shown in Figure
36.
All fixtures and fittings can be fixed to the framing timbers forming the
panels. Extra noggings can be added to support heavy fixtures such as wash
basins or boilers.

Hole 25 mm dia.

Electric socket fixed

blllcking SO x SO

Figure 35. Internal wiring

 Joist ~7 K 145

-......_,,--_ Pipe

Bearer 41 x 194

Figure 36. Drilled holes in joists

Finishing touches

Plywood skirtings of size 9 x 100 mm, for the main building can be fixed
between the wall and the floor. Plywood beadings of 9 x 72 mm are used to
cover all jointings between the plywood pieces.
Finally the whole building can be painted. The primary function of painting
the wall is to protect the surface, for easy cleaning and to maintain appearance.
Wood surfaces exposed to the weather withou t any finish, will quickly change;
hence they need finishing both for appearance and protection.
For floors, the natural colour and grain of wood make them attractive and
beautiful. The application of floor finishes should protect the surface from
excessive wear and abrasion, and make it easier to clean.
The building now can be occupied.

,.,,,
 Chapter 7

MAINTENANCE AND REPAIR

A house if properly designed and constructed with adequate attention given

to details and to proper choice of materials used as outlined in this handbook,
would require little maintenance. The following are some of the suggestions
that may be followed to reduce the cost of maintenance. However, it must
always be borne in mind that the two points to ponder are deterioration of
timber house caused by termite attack which is mostly found in the tropics and
decay caused by moisture and dampness.

Raised platform

(1) Space beneath the platform should be well ventilated. Open spaces must
not be blocked by obstacles, including grasses, shrubs and planting.
(2) No water should be allowed to collect under the building. Hence the
gradient of the soil should slope away from the house.
(3) Make sure the top of all concrete surfaces such as concrete footings, stair
landing and kitchen floor should be between 50 and 100 mm above the
ground level as per original design.
(4) Inspect regularly the surrounding area of the house for signs of termite
activity. Break the earthen termite tunnel if found because subterranean
termites can only survive if there is a connection between the soil and the
building. If possible treat the soil with insecticidal solution to prevent
termite infestation.

Exterior walls

(1) No part of the building should be allowed to collect water as this

increases the moisture content of the wood or plywood therebyencour-
aging the growth of fungi and causing wood decay or rot. Such damages
are common on door and window frames.
(2) Look for cracks or gaps in the exterior wall due to shrinkage or poor
workmanship. Seal up the cracks by applying putty.
(3) If non-corrosive nails were used in the construction of the building and
were driven flush with the heads exposed rust spots may occur at the
nailheads. The remedy for this is to set the nailhead below the surface
and apply putty to cover up the head.
(4) If the painting or finishes of the wall surfaces show signs of deterioration,
apply fresh coats of paint.

Interior

(1) If there are cracks in the interior walls, fill the cracks with putty and paint
over as in exterior walls.
(2) Do not allow moisture to remain long on the surface of any timber or
plywood especially in the kitchen area.
(3) The sheathings of wall panels may be accidentally damaged resulting in
holes or cracks in the sheets. If the holes are small they may be filled up
with putty and sanded smooth. Larger holes may require cutting a
section around the damaged portion and replacing it with a new section.
(4) Gaps may form between the floor boards due to shrinkage of the boards
because they were originally laid with very high moisture content. One
remedial action is to fit matching strips of timber between the flooring
strips and glue them in place. In severe cases it may be necessary to
replace sections of the floor.

Roof

(1) Stains in the ceiling boards will indicate that the roof is leaking. Check
position of leaks and repair the roof.
(2) Make sure air circulation is maintained in the enclosed roofing area by
seeing that ventilation openings at the two gable ends are provided and
not blocked.

An
References

Uniform Building By-Law 1984. Printed by MDC Sdn. Bhd.

Code of Practice for the Structural Use of Timber. Malaysian Standard. M.5. 544: 1978.
Standard and Industrial Research Institute Malaysia (SIRIM).
The Malaysian Grading Rules for Sawn Hardwood Timber, (MGR). The Malaysian Timber
Industry Board, 1984.
 !
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210 8"",
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230 240 8"", 260 26 18 - 21 47 x 72 Ply' 6mm Ply· 6m
17, 27d
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22 -24,26-27 47 x 97 Gem. 10 mm Gem. 8m

25 47 x 72 Cem. 8mm Cem. en

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9 mm plywood to be of WBP typ"
6 mm plywood to b. of MR type
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n expansion g~p between sneath"lngs
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Kitchen Partition
FrafM eJl 47.112
PlywoOd MR 6 "'"",

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Insid'
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Naco IOuYrtS
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SECTION A-A 101(9'16 of 9 l' 100 SECTION B - B
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DETAIL OF POST & BEARER

Pifct ')0 • ')0 10 Slilt~n

joisl (ue del ail a bovt I
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Tread 47. 2':10 Bolt 1,).g dia. . Splice 2/10. ,94_440
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VIEW C
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POST & ENTRANCE STAIRS r n.... .... I t" __ ,_

 ;or-i~i;;~;~i ~;~I"'~'~;n--oth;; .n·d··~~ . . t!rt!d ..... ith
Umbaard bUding 6 mm thick • 100 mm wide

ii! Galva,""sed melat platt!

lmm thick O,ill or punch hol.,
2·6 mmiJ- lor 2·6. SO
n.ils
adlillct!nt pane!

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lor tilting p~".ts

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1'0 1" 1 :: I " , '0 1
CONNECTION OF PLYWOOD
ANGLE PLATE FOR CEMBOARD PLATE JOINING
CORNER PANELS
CORNER PANELS CEMBOARD PANELS
(F.S.) (F.S.)
] Nos. ~t."aniUd slt!el plait!

Wall plilllt! PI dbt!ad' 9.72 I Plywood bfading 9 • 72 10 Wall plllt! eo. 80 (sPe above ) fixed
on t!lII:lt!rior side
1.7.112
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Cone.lloor
,wOOd SIl"I'"g pl;lt~(6).89>G> sPIcing tOOmm NAILING PATTERN OF PANEL
)0 mm 9 • lOO on b/, on exterior ,idt! only Olwel bar 12 mm • • 'i0 mm
@ 610 en Slu or nlit,: 2.~. \0
ELEVATION (F. S ) Edge diSfJln~: 12 mm
CONNECTION OF CEMBOARD WALL PANELS Spacing: I'f'fi~"f: I~O mm
( F.S.) Inl~~iJll': lOOmm

Org. No· Scal •.

CONNECTION OF PLYWOOD WALL PANELS 101/94/8 of 9 I, 20
 All truss members
iJ 35 • 72

1923 1924 1923

860 5770

Plywood gussl?t 9mm h/s with:

TRUSS DETAIL (View V) Nails 3·3 x 63
2415 Spac ing a-long gri!lin =~6 rrm
. - - - . - - - - Additional beams Spacing per. to gr =23 mm
" 4500 • 35 • 72
1 1 Edge dist =16 mm
(J) denote: No of nails = 7
~~~~~- Horizantal brace
22 • 97
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22.97

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point
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35.72
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Panels CD to @ Plywood sheZlthing 9 mm & 6 mm thick

Panels @ to
® Cemboard she.athing lOnvn & 8 mm thick

Studs .7 x 97 and .7 x 72

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Panel ® Panel ® PLAN Panel CD Panel CD Panel @ Panel@

ELEVATiON

Panel (2)

DOUble
vOla 01. VOID (01. VOID col·

ELEVATiON ELEVATiON
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ISBN 983-9592-55-6

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