Design for

Manufacturing and
Assembly (DfMA)
Prefabricated Prefinished
Volumetric Construction
Contents
Chapter 1
Introduction 6
Chapter 2
PPVC Considerations and Key Factors 10
2.1 Early Involvement of Contractors
2.2 Types of PPVC Modules
2.3 Transportation
2.4 Configuration of PPVC Modules
2.5 Type of Hoisting Machinery
2.6 Comparison of Reinforced Concrete (RC) Module and Steel Module

Chapter 3
Design Considerations 18
3.1 Architectural Design Considerations
3.1.1 Modularisation
3.1.2 Early Coordination
3.1.3 Dimension on Plan
3.1.4 Dimension on Section
3.1.5 Vertical and Horizontal Alignment
3.1.6 Water-Tightness Between Modules
3.1.7 Consideration of Construction Tolerance
3.2 Structural Design Considerations
3.2.1 Structural Modelling
3.2.2 Vertical Modules Connection
3.2.3 Horizontal Modules Connection
3.2.4 Structural Robustness
3.2.5 Modules Connection to Civil Defense Shelter Wall
3.2.6 Structural Design of Modules
3.2.7 Periodic Structural Inspection (PSI)
3.3 Mechanical, Electrical and Plumbing (MEP) Design Considerations
3.3.1 Electrical
3.3.2 Lightning Protection
3.3.3 Water
3.3.4 Sanitary
3.3.5 Air-Conditioning & Mechanical Ventilation
3.3.6 Town Gas
3.4 Compliance with Fire Safety Requirements
3.4.1 Compliance of Fire Compartmentation
3.4.2 Compliance of Use of Material

Prefabricated Prefinished Volumetric Construction 1

Chapter 4
PPVC Module Production 38
4.1 Reinforced Concrete (RC) PPVC Production
4.1.1 Mould Process
4.1.2 Structural and MEP Works
4.1.3 Architectural Finishing and MEP Works
4.2 Steel PPVC Production
4.2.1 2D And 3D JIG
4.2.2 Fabrication Process

Chapter 5
Protection, Transportation and Lifting 56
5.1 Transportation Plan
5.2 Packaging, Protection and Labelling
5.3 Module Cover (Temporary or Permanent)

Chapter 6
Construction and Project Management 58
6.1 Location of the Project and Adjacent Areas
6.2 Access and Traffic Management for Trailers with Heavy Cargo
6.3 Consideration of Just-In-Time (JIT) Operation
6.4 Types of Cranes
6.5 Safety

Chapter 7
Installation 62
7.1 Access and Egress
7.2 Vertical and Horizontal Alignments
7.3 Sequencing of the Modules Installation
7.4 Safety

2 Design for Manufacturing and Assembly (DfMA)

Chapter 8
Critical Inspections and Quality Checks 64
8.1 Quality Checks
8.1.1 Reinforced Concrete PPVC
8.1.2 Steel PPVC
8.2 Structural Works
8.3 MEP Works
8.4 Architectural Works

Chapter 9
Maintenance, Replacement and Renovation 72
9.1 Renovation
9.1.1 Homeowner User Manual

Chapter 10
Regulations 74
10.1 List of Regulators
10.2 Minimum Level of Off-Site Work for PPVC
10.3 Building Innovation Panel (BIP) and PPVC Manufacturer Accreditation Scheme (MAS)
10.4 Code of Practice and Good Industry Practice Guidebooks (References)
10.5 Design for Safety
10.5.1 Access/Egress
10.5.2 Choice Between Fall Prevention, Fall Restraint and Fall Arrest System
10.5.3 Module Installation and Alignment
10.5.4 Useful Resources

Appendix
Some PPVC Projects References in Singapore (completed and ongoing)

This guide may be used for reference purposes only. The contents of this guide are protected by copyright and other
forms of proprietary rights owned by, licensed to or controlled by BCA and shall not be reproduced, republished,
uploaded, posted, transmitted or otherwise distributed in any way, without the prior written permission of BCA.
Modification of any of the contents or use of the contents for any other purpose will be a violation of BCA’s
copyright and other intellectual property rights. Any reference herein to any specific commercial products, process,
or service by trade name, trademark, manufacturer, or otherwise, does not constitute or imply BCA’s endorsement
or recommendation.

“All content used herein is for non-profit educational purposes. Where possible, all credit has been given to the
respective owners or creators of the content.”

Prefabricated Prefinished Volumetric Construction 3

Foreword
Under the Construction Industry Transformation Map, we are transforming Singapore’s built environment
sector into one that is technologically advanced and highly productive. BCA has identified the Design for
Manufacturing and Assembly (DfMA) approach as a key strategic thrust to raise the construction productivity.
This Prefabricated Prefinished Volumetric Construction (PPVC) guidebook is the first installment of a series
of guidebooks on DfMA technologies. This guidebook will share on key aspects of PPVC and associated good
practices, hence allowing practitioners to appreciate and reap the full benefits of off-site manufacturing.
Besides the possibility for earlier project completion, end users can enjoy high quality works given that
most of the works are carried out in a controlled factory environment.

This guide provides simple and practical tips to practitioners on how PPVC is designed, fabricated, inspected,
delivered and installed to achieve its functional requirements and workmanship standards. Good practices
such as upfront planning and design to incorporate PPVC adoption will also be covered. When constructed,
such PPVC buildings would be no different from conventional buildings and can have creative design and
interesting facades.

As this is an evolving technology, this guide is not meant to be a definitive publication on how PPVCs must
be designed and installed. Practitioners are encouraged to use this guide to innovate and improve further
on PPVC design, fabrication and installation. To obtain more comprehensive information and guidance,
readers should seek professional advice from designers and suppliers of PPVCs. We gratefully acknowledge
the contributions of key technical agencies and practitioners in the production of this guide and trust
that the industry will find this publication useful. We welcome any contributions from readers to improve
subsequent editions of this guide.

NEO CHOON KEONG

Deputy Chief Executive Officer
Industry Development
Building and Construction Authority

4 Design for Manufacturing and Assembly (DfMA)

Acknowledgement
This Prefabricated Prefinished Volumetric Construction (PPVC) Guidebook was developed by the Working
Committee in close collaboration with key technical agencies and industry representatives comprising
Architects, Builders, Consultants, and Specialist Contractors.

A Technical Committee, comprising members from various industry associations and organisations, was
formed to review the contents.

We wish to thank all members of the technical agencies as well as the Technical and Working Committee
for their valuable contributions.

TECHNICAL COMMITTEE:
Mr Ramamoorthy Rajendran Building and Construction Authority (Chair)
Er Siew Hoong Kit Nanyang Technological University (Co-Chair)
Ms Tay Seok Cheng REDAS (Co-Chair)
Er Chee Kheng Chye Housing and Development Board
Er Chan Ewe Jin Institute of Engineers
Mr Kenneth Loo SCAL
Ar Richard Lai Singapore Institute of Architects
Ar Yeo Eng Choon Singapore Institute of Architects
Mr Tan Chin Hock ACES
Mr Wong Soon Tuan Dragages Singapore Pte Ltd
Mr Eddie Kua Tiong Seng Contractors Pte Ltd
Mr John Mo Moderna Homes Pte Ltd

WORKING COMMIT TEE:

Ms Mika Feng Building and Construction Authority (Lead)
Mr Lee Choon Shung ADDP Architects LLP (Co-lead)
Er Liew Ve Koon P&T Consultants Pte Ltd
Mr Johnny Lim Teambuild Engineering & Construction Pte Ltd
Mr M.Bhvvanesvaran Integrated Precast Solutions Pte Ltd
Mr Lee Chong Whey Moderna Homes Pte Ltd
Mr Sean Tan Huei Chong Vico Construction Pte Ltd
Ms Toh Xing Juan Building and Construction Authority
Mr Louis Chong Building and Construction Authority
Mr Jonathan Kok Building and Construction Authority
Mr Neo Seng Hai Building and Construction Authority
Mr Han Wann Kuang Building and Construction Authority

TECHNICAL AGENCIES:
Ministry of Manpower Jurong Town Corporation
Singapore Civil Defence Force Urban Redevelopment Authority
Public Utilities Board Housing and Development Board
National Environmental Agency Land Transport Authority

ANG LIAN AIK

Group Director
Construction Productivity and Quality Group

Prefabricated Prefinished Volumetric Construction 5

Chapter 1

Introduction
To raise construction productivity and fundamentally change the design and construction processes, the
industry is encouraged to embrace the concept of Design for Manufacturing and Assembly (DfMA), where
construction is designed and detailed for a substantial portion of work to be done off-site in a controlled
manufacturing environment.

DfMA is a new approach in the construction industry. By planning more works offsite, manpower and time
needed to construct buildings are reduced, while ensuring work sites are safe, conducive and have minimal
impact on the surrounding living environment. The use of prefabrication methods in construction has been
promoted as a way to improve productivity in a traditionally manpower-intensive industry.

6 Design for Manufacturing and Assembly (DfMA)

Prefabricated Prefinished Volumetric Construction (PPVC) is one of the game-changing technologies
that support the DfMA concept to significantly speed up construction. Modular is a general construction
term to describe the use of technology that facilitates off-site manufacturing. Complete modules made
of multiple units complete with internal finishes, fixtures and fittings are manufactured in factories,
and are then transported to site for installation in a Lego-like manner. In the hierarchy of DfMA
methodologies, PPVC is one of the most efficient and complete principles in improving productivity.

In this book, the DfMA methodology on PPVC and the benefits reaped will be discussed so that there
is better knowledge and capability in the adoption and implementation of PPVC.

Pushing for Higher-end DfMA Technologies

Components: CONTINUUM OF PREFABRICATION & DFMA Integrated assemblies:
Incremental Improvement game-changing improvement

Prefab Components Advanced Prefab Systems Integrated Sub-Assemblies Fully integrated Assemblies
Structural

Precast Structural Steel/ Mass Engineer Timber PPVC

Advanced Precast/Hybrid (MET)/Hybrid

Manpower Savings
(Project Level) 10% 20% 35% 40%
Architectural

Engineered
Wallpaper timber floor
On-site Dry Applied Finishes Prefinished Surfaces PBUs PPVC

Manpower Savings
(Trade Level) 30% 45% 60% 70%
MEP

Flexible Water Pipe/ Prefab Ceiling Module/ Prefab Module with PPVC
Sprinkler Dropper Prefab Plant Platform/Catwalk

Prefabricated Prefinished Volumetric Construction 7

 Comparison
CONVENTIONAL CONSTRUCTION PREFABRICATED PREFINISHED
VOLUMETRIC CONSTRUCTION ( PPVC )

In a traditional manpower-intensive industry, “Prefabricated Prefinished Volumetric

most of the trade works involving structural, Construction (PPVC)” means a construction
architectural, MEP and interior finishing works method whereby free-standing volumetric
are constructed and installed on site. modules (complete with finishes for walls, floors
and ceilings) are:

a. constructed and assembled; or

b. manufactured and assembled,

in an accredited fabrication facility, in accordance

with any accredited fabrication method, and then
installed in a building under building works.

8 Design for Manufacturing and Assembly (DfMA)

Benefits of PPVC

PRODUCTIVITY IMPROVEMENT REDUCTION OF ON - SITE MANPOWER

• Fabrication of PPVC can proceed in • This will enhance worksite safety and direct the
parallel in the factory while other worksite manpower to better working conditions. More
activities are ongoing to streamline the construction off-site leads to less time on-
construction process. site and fewer individual man-hours working
• The on-site construction activities can be at height.
significantly reduced through the use of PPVC. • By reducing construction and installation
• It can potentially achieve a productivity activities and manpower from the site, and
improvement of more than 40% in terms of placing them off-site in a controlled factory
manpower on site and more than 20% time environment, fewer workers will be on site
savings, depending on the complexity of which in turn leads to fewer accidents and
the  projects. less downtime.

BETTER CONSTRUCTION ENVIRONMENT BETTER QUALITY CONTROL

• As more activities are done off-site, a • PPVC delivers the majority of the final product
reduction of environment pollution can be from the controlled factory environment
ensured as dust and noise pollution are leading to increased reliability with higher-
potentially minimised. quality finishing.
• Disamenities to the surrounding • Sequence of work can be planned more
neighbourhoods during construction can efficiently with better logistics coordination.
be diminished.
• Prefabrication of the building modules also PPVC can be considered for multi-room
leads to cleaner worksites by generating less accommodations such as:
overall construction waste on-site. • Residences
• Institutions
• Hotels and hostels
• Nursing homes
• Dormitories

Prefabricated Prefinished Volumetric Construction 9

Chapter 2

PPVC Considerations and Key Factors

2.1 Early Involvement of Contractors
• Given that each PPVC Fabricator has their own proprietary system for the manufacture of PPVC modules,
it is highly encouraged to engage the PPVC Fabricator as well as the Main Contractor early upfront during
the design stage to allow their inputs into the design for a better and more effective technical solution.
• The Design and Build (D&B) and Design Development and Build (DDB) procurement models can be
adopted for PPVC projects as they allow greater inputs into the design upfront by the Main Contractor
and their PPVC Fabricators. This will vastly increase the buildability and constructability of the PPVC
design, leading to greater productivity in construction.

2.2 Types of PPVC Modules

The choice of material will dictate the size and number of modules in the design as weight is a major
consideration for the hoisting of the modules.

Other major factors will involve logistics of transportation, site layout and holding area, crane or
hoisting  position.

Material

1 2
Characteristic of module Concrete Steel

Weight Heavy Light

Limit by crane reach and capacity due to weight

10 Design for Manufacturing and Assembly (DfMA)

 1 2
REINFORCED CONCRETE PPVC MODULE STEEL PPVC MODULE

Wall: Concrete Wall: Steel frame with lightweight walls

Floor: Concrete Floor: Concrete or Lightweight Flooring System

2.3 Transportation
Logistics for modules transportation from factory to site will determine the maximum size and volume of
each module design, which in turn affects the number of modules to complete the layout design.

The size of a single module should be limited to the dimensions allowed to be transported on public road
without requiring special measures such as police escort. Height consideration has to be factored in if the
route involves passing through overhead bridges.

In compliance to LTA‘s traffic regulatory requirements, Police Escort will not be required, when the
parameters are controlled.

Height < 4.5 metres (inclusive of truck height)

Width ≤ 3.4 metres

Laden Weight < 80 tons

Prefabricated Prefinished Volumetric Construction 11

Existing road configuration around the site has to be analyzed for the maneuvering and holding of the
modules. The deliveries have to be planned and coordinated to avoid congestion outside the site especially
for urban built-up areas.

Width

Height

Figure: Transportation truck.

(Note: Dimensions are for reference only.)

12 Design for Manufacturing and Assembly (DfMA)

2.4 Configuration of PPVC Modules
The modules are configured according to the design layout. The geometry of the modules can be simplified
to design for ease of production.

The number of modules will vary, depending on the residential unit typology (Studio, 1 to 5 rooms). Total
number of modules can typically range from 1 to 8 numbers per unit.

Demarcation of a typical unit module with reference to plan below is as follows:

• Module A: LRDIN (Living and Dining Room)
• Module B: B2-IBB (Bedroom 2 with In-built Bathroom)
• Module C: MB-IBB (Master Bedroom with In- built Bathroom)
• Module D: KIT (Kitchen)

Module A
LRDIN

Module D
KIT

Module B
B2-IBB

Module C
MB-IBB

Figure: Example of A Typical 2-Bedroom Unit Modules (Plan View)

Prefabricated Prefinished Volumetric Construction 13

 D: KIT

B: B2-IBB A: LRDIN

C: MB-IBB

Figure : Example of A Typical 2-Bedroom Unit

Modules (3D View)
MODULE A : LRDIN MODULE B : B2-IBB
MODULE A : LRDIN Living and Dining RoomMODULE B : B2-IBB BEDROOM 2 with In-built Bathroom
Living and Dining Room BEDROOM 2 with In-built Bathroom

MODULE A : LRDIN MODULE A :CLRDIN

MODULE A: MODULE B:
MODULE MODULE
: MB-IBB B : B2-IBB
MASTER MODULE C : MB-IBBMODULE C:
MODULE
MASTER B : B2-IBB
Living and Dining Room Living and Dining
BEDROOM Room
BEDROOM
with 2 withBEDROOM
In-built Bathroom In-built Bathroom BEDROOM
with In-built Bathroom2 with In-built Bathroom MODULE D:
LRDIN B2- IBB MB - IBB
KIT
Living and Bedroom 2 Master
Kitchen
Dining Room with In-built Bedroom
Bathroom with In-built
Bathroom

MODULE C : MB-IBB MASTER MODULE C : MB-IBB MASTER

BEDROOM with In-built Bathroom BEDROOM with In-built Bathroom

14 Design for Manufacturing and Assembly (DfMA)

Modules can be configured to meet the functional requirements of the building. A typical bedroom of a
nursing home can constitute a total of 4 standard modules, to achieve the functional requirements.

Demarcation of a typical unit module with reference to plan below is as follows:

• Module A: 1MA
• Module B: 1MB
• Module C: 1MC
• Module D: 1MD

Module A
Bed Bed
1MA

Module B
Bed Bed
1MB Figure: Example of Woodlands Nursing Home PPVC
modules (3D View), combined to form a bedroom
3D Courtesy of Dragages (Singapore) Pte Ltd

Module C
Bed Bed
1MC

Module D
Bed Bed
1MD

Figure: Example of Typical Bedroom at Figure: Photo of a completed Typical

Woodlands Nursing Home (Plan View) Bedroom at Woodlands Nursing Home
Plan Courtesy of Dragages (Singapore) Pte Ltd (with seamless wall and floor joints)
Photographs Courtesy of Dragages
(Singapore) Pte Ltd

Prefabricated Prefinished Volumetric Construction 15

2.5 Type of Hoisting Machinery
Sizing and arrangement of cranes on a site will be dictated by the total lift weight of the module and the
reach of the crane.

Below are some generic information on the type of cranes available.

Characteristic of
Crane
Tower crane Mobile crane Crawler crane

Crane Capacity 50 tons 700 tons 500 tons

Lifting Capacity 25 tons – 40 tons 25 tons – 40 tons 25 tons – 40 tons

Height of Equipment 120m 40m 80m

Radius of work 40m 40m 40m

Note: Actual crane requirement and capacity shall vary according to the
site condition and to be obtained from the crane specialist accordingly.

16 Design for Manufacturing and Assembly (DfMA)

2.6 Comparison of Reinforced Concrete (RC) Module and Steel Module

1 2

Reinforced Concrete Module Steel Module

Weight 20 to 35 tons 15 to 20 tons

• Protection for completed modules • Protection for completed modules

Handling and • Permanent / temporary roof decking • Permanent / temporary roof decking
Transportation • May require temporary stiffening • May require temporary stiffening
• Require lifting frame • Require lifting frame

Installation
Stacking method Stacking method
Method

Hoisting Machinery Hoisting by crane Hoisting by crane

Familiarity to
Renovators in
To include information of
Maintenance, Similar to conventional construction
supplier manual
Replacement /
Renovation Works

Fire
Compartmentation and use of materials
Compartmentation Similar to conventional construction
shall comply with the applicable Code
/ Rating

Provision for
Barrier-Free
Similar to conventional construction Similar to conventional construction
Accessibility
Requirements

Note: For reference only.

Prefabricated Prefinished Volumetric Construction 17

Chapter 3

Design Considerations
3.1 Architectural Design Considerations
3.1.1 Modularisation

• At the unit layout planning and design stage, the PPVC modularisation must be undertaken in tandem
with the unit layout design as early as possible. Early PPVC vendor’s and engineer’s involvement will be
beneficial to the project. The modularisation is largely affected by the configuration, sizes, dimensions,
weights of PPVC modules and ease of transportation.
• The weight of module in turn depends on the choice of PPVC material type, level of finishing, etc.
The transportability of modules would be influenced by the planned delivery routes (i.e. from off-site
prefabrication plants to the construction site) and types of trailers available in the industry.

Lift Lobby Lift Lobby

Figure: Example of PPVC modularisation during planning stage (Residential Block Plan)

18 Design for Manufacturing and Assembly (DfMA)

3.1.2 Early Coordination

• Early coordination among Developer, Architect, Structural Engineer and MEP Engineer, Builder and PPVC
specialist are essential as this will allow the team to look into the key design aspects upfront including
layout design, floor and ceiling height, etc.
• With proper upfront planning to integrate PPVC into the design layout, unique designs and different
building features such as curved facade and non rectangular layout can be achieved.
• To consider the removable of non-structural partitioning wall in design for future renovation.

3.1.3 Dimension on Plan

• To ensure the layout plan design comply with regulatory requirements.

• To ensure the size of modules allow transportation from factory to site.

Length of Module

LRDIN
Width of Module

KIT

B2-IBB

Demountable non-structural
partitioning wall
MB-IBB

Figure: Typical 2-Bedroom Unit Modules.

Prefabricated Prefinished Volumetric Construction 19

3.1.4 Dimension on Section

• To ensure the floor-to-floor height comply with regulatory requirements.

• To ensure the size of modules allow transportation from factory to site.
• To comply with regulatory requirements of ceiling height.
• To consider the usage of single or double slabs.
• To maximise the useable room space and ceiling height.

MEP ZONE FCU

False ceiling

Ceiling height Height of module

Floor slab

MODULE 1 MODULE 2

Figure: Typical Sectional Detail of Modules

Note: For reference only.

20 Design for Manufacturing and Assembly (DfMA)

3.1.5 Vertical and Horizontal Alignment

• To consider the possible misalignment of floor, wall, ceiling at joints between modules.
• To consider the interfacing details between PPVC modules and in-situ construction such as
core walls, staircases, corridors, and other portions of buildings.

LRDIN
Possible vertical /
horizontal
KIT misalignment of
floor and wall
finishes at joints
B2-IBB
between modules.

MB-IBB

Figure: Typical 2-bedroom Unit Plan

Possible misalignment of
ceiling finishes at joints
between modules.

Possible misalignment of
floor and wall finishes at
joints between modules.

MODULE 1 MODULE 2

Figure: Typical Sectional Detail of Modules

Prefabricated Prefinished Volumetric Construction 21

3.1.6 Water-Tightness Between Modules

• To consider the water-tightness details on vertical and horizontal joints of modules

LRDIN

Vertical /
KIT horizontal
joints between
modules

B2-IBB

MB-IBB

Figure: Typical 2-bedroom Unit Plan

22 Design for Manufacturing and Assembly (DfMA)

3.1.7 Consideration of Construction Tolerance

• To consider and allow construction tolerance on vertical and horizontal joints of modules and in-situ part.

Vertical
Joint

Horizontal
Joint

Figure: Vertical and Horizontal Joint

Prefabricated Prefinished Volumetric Construction 23

3.2 Structural Design Considerations
3.2.1 Structural Modelling

3D modeling of building structures shall be carried

out using suitable computer analysis software.
In situations where module columns or walls are
abutting each other, such configuration should be
considered in the 3D modeling.

In addition to the permanent design action

conditions, extra modeling should be carried out to
the PPVC modules with the designated number of
lifting points included as temporary conditions (i.e.
during hoisting operation)

Figure: Structural Modeling For High Rise

Building With PPVC

24 Design for Manufacturing and Assembly (DfMA)

3.2.2 Vertical Modules Connection

The vertical modules connection is crucial for the structural behaviour especially for high rise buildings.
They have a direct effect on the building stiffness and its corresponding response under the wind, seismic
(if applicable) and lateral design action conditions. Hence, the detailing of the PPVC vertical connection
must satisfy the design intent.

Vertical joints are to be designed for eccentricity or imperfection in accordance with the Building
Code Requirement.

3.2.3 Horizontal Modules Connection

The horizontal modules connection forming the floor diaphragm, are equally important, contributing to
the overall building stiffness. In particular, the peripheral ties and internal ties shall be provided as per
the Building Code Requirements. The PPVC modules and layout shall be laterally connected and designed
such that the horizontal forces (e.g. wind load) can effectively be transferred to the building’s lateral load
resisting system.

Due to the repetitions, and as far as practicable, the horizontal joints should be designed in a manner that
the implementation at site would be speedy and simple. A classic example for steel PPVC module joints is
the bolting system, whereas in concrete PPVC on-site grouting of joints is common.

3.2.4 Structural Robustness

The design of PPVC building shall give due consideration to the scenario of sustaining an extent of localised
failure without disproportionate collapse. The inter-connected volumetric system must be capable of
redistributing the internal forces to the nearest load bearing elements such that progressive collapse is
totally prevented.

Provisions for structural robustness may involve providing effective horizontal and vertical ties, notional
removal of one column / nominal section of wall or designing such elements as a “key element” or systematic
risk assessment in accordance with the building’s Categorisation of Consequences Classes as per relevant
EN 1991-1-7 provisions.

Prefabricated Prefinished Volumetric Construction 25

3.2.5 Modules Connection To Civil Defence Shelter Wall

It is mandatory for residential building projects to incorporate either Household Shelters (HS), Storey
Shelters (SS) or Staircase Storey Shelters (SSS) as Civil Defence (CD) Shelter. In situation where PPVC
modules are abutting the CD shelter, effective connection for load transfer between the abutting PPVC
modules and CD shelter walls at each storey level is to be provided. The connection details should take into
account the construction sequence of shelter walls, launching of precast staircase flights (for SSS), casting
of shelter floor slab and installation of abutting PPVC module(s), hollow cores formed in the precast hollow
core shelter walls, as well as the installation of steel reinforcement cages inside the hollow cores at site.

Lift Core &

Staircase
Storey
Shelters

PPVC Modules

Figure: Modules Connection to Civil Defense Shelter.

Note: To Refer to Relevant Technical Requirements

26 Design for Manufacturing and Assembly (DfMA)

3.2.6 Structural Design of Modules

In addition to the normal elemental design under the permanent design actions, it is necessary to carry
out structural analysis of transient design situation (e.g. during handling in the prefabrication plant) to the
PPVC modules considering the designated lifting points during hoisting and erection. Serviceability limit
checks should be performed to prevent cracks to the concrete slab, walls or steel frame distortion during
handling and transporting.

The lifting points must be strategically positioned such that sufficient bond anchorage can be developed
to hoist the entire module safely and that the load distribution to all lifting points is reasonably uniform. It
is a good practice to hoist PPVC module with the aid of steel collar frame so that the module would not be
subject to inclined forces from the lifting wires.

Broadly there are two types of framing system for concrete PPVC modules, namely:
a. Beam-Column system, in which the beam profiles may be visible without false ceiling.
b. Slab-Shear wall system, in which no beam is required for the module framing

Lifting Hooks
Lifting Collar Frame

Figure : Modules with Lifting Collar Frame and Hooks

Prefabricated Prefinished Volumetric Construction 27

3.2.7 Periodic Structural Inspection (PSI)

Periodic Structural Inspection (PSI) is a requirement for all buildings, be it steel or concrete. However, for
Steel PPVC modules, there is an additional access panels with inspection points required to conduct the
inspection on critical structures such as steel beams and column joints. These inspection points and the
proposed inspection methodologies shall be identified at the onset and be included in the structural plans
for fabrication and for authority submission.

To minimise the inconvenience to the building occupiers when the Structural Inspector conducts the
inspection in future, these inspection points shall be strategically planned and located at areas that are
discreet such as balconies, ac ledges, kitchens or common corridors.

Figure: Example of PSI Point Provision

Photographs Courtesy of Surbana Jurong Pte Ltd and Moderna Homes Pte Ltd

28 Design for Manufacturing and Assembly (DfMA)

3.3 Mechanical, Electrical and Plumbing (MEP) Design Considerations

TYPICAL MEP SERVICES MEP COORDINATION IMPACT TO STRUCTURE

Electrical, lightning protection, Early coordination of services will AND FIRE SAFETY
water supply, sanitary, ACMV, be advantageous. Constraints for Necessary openings, recesses
gas, and any other system are installation and maintenance and concealed components
part of PPVC. should be addressed early to avoid shall be included in
impact on pre-finished works in consideration for structural
the later stage. Upfront design strength, fire safety measures
coordination in conjunction and other relevant design.
with structural prefabrication
component is important.

INTEGRITY OF MEP ACCESSIBILITY FOR DESIGN AND

SERVICES INSTALLATION AND CONSTRUCTION ERRORS
Continuity and system MAINTENANCE Tolerance of gradient of pipe-
integrity of all MEP services Means of installation shall enable works connections shall be
shall be taken care of. Due ease of maintenance or future considered. Angle and leveling
to the modularisation nature replacement when necessary. of fittings may be affected
of PPVC, connection of MEP Space for installation, maintenance after the module is positioned
system components between and future replacement shall be in-place. Design and planning
modules may be required. allocated. Pipework enclosures shall consider tolerance of
Connection methodology shall (e.g. ducts, castings, etc.) shall these level differences.
not compromise integrity and be of a suitable size. Sufficient
performance of the system. and suitable ready access shall
be provided for maintenance,
inspection, testing and repairing /
replacing of the enclosed pipework.

Prefabricated Prefinished Volumetric Construction 29

 MEP Design Considerations

Water supply Cable containment

Sanitary discharge
Refrigerant
pipe for air-
conditioning

PLAN

Figure: Sample of Concealed

SECTION Services in the Ceiling Space

30 Design for Manufacturing and Assembly (DfMA)

3.3.1 Electrical

• Connection of components including conduit, cable trunking and cable trays.

• Joint of cable infrastructure between modules to ensure proper protection for cable.
• Joint of cable shall ensure complete continuity with acceptable connection methodology,
if joint of cable is unavoidable.
• Concealed cable infrastructure not to compromise fire safety.

PPVC
MODULE 1
Penetration between PPVC modules
Junction box

PPVC
MODULE 2

Figure: Electrical Services

Prefabricated Prefinished Volumetric Construction 31

3.3.2 Lightning Protection 3.3.3 Water

• Connection of lightning conductor. • Water fittings that are to be concealed shall

• Connection joint shall ensure proper be water-tight and suitable for the default
conductivity with acceptable methodology. conditions (e.g. pressure, temperature and
• If structure rebar and/or structural steel section etc), which is likely to be encountered by the
is used as conductor, proper measures to be water fittings.
taken to prevent erosion of conductor. • Concealed components embedded in
structural elements shall be taken into
consideration for structural strength design.

PPVC
MODULE 1
UPPER
PPVC Hot / Cold
MODULE water supply
pipe

Penetration
between
Lightning modules
conductor
PPVC
MODULE 2

LOWER
PPVC
MODULE

Figure: Lightning conductor

connection between modules

Figure: Water supply routing and

connection between modules

32 Design for Manufacturing and Assembly (DfMA)

3.3.4 Sanitary

• All sanitary discharge pipes and ventilating pipes shall be laid in accordance with PUB and Code of
Practice requirements.
• All gravity discharge pipes shall have suitable gradient to maintain self-cleansing velocity to ensure
smooth flow.
• All joints of pipes shall be tested to ensure water-tightness and air-tightness.
• Shallow floor trap shall be of the suitable type and comply with the performance standards prescribed by
PUB. For shallow floor trap requirements, please refer to Code of Practice on Sewerage and Sanitary Work.
• Shallow floor trap shall not be used if there are connections from kitchen sink or dishwasher.
• To consider potential slab thickening factor for use of shallow floor trap (subject to regulatory compliance
and approval), including impact on weight, transportation and storage requirements.
• Proper protection to all protruding and exposed pipeworks from mechanical damage during transportation,
storage and shifting of modules.
• To protect pre-installed pipeworks from heat, ultra-violet radiation and other possible detrimental factors.
• Concealed components embedded in structural elements shall be taken into consideration for structural
strength design.
• To ensure suitable access and working space provided for pipe connection between modules.
• Method for future repairing works for clogging or leakage shall be taken into consideration in the design.
• To consider mounting type of WC (floor-mounted or wall-mounted).

Prefabricated Prefinished Volumetric Construction 33

 Sanitary

CONVENTIONAL FLOOR TRAP

SHALLOW FLOOR TRAP

34 Design for Manufacturing and Assembly (DfMA)

3.3.5 Air-Conditioning and Mechanical Ventilation

• Connection of air-conditioning components including refrigerant pipe, condensate drain pipe, respective
insulation layer, and wiring.
• Joints of refrigerant pipe, if required, shall be able to withstand operating pressure and not be
eroded easily.
• Maintenance and repairing measures shall be taken into consideration.
• Connection of mechanical ventilation components including mechanical fan, air-duct and wiring.
• Inspection and replacement access for equipment such as mechanical fan shall be reserved.

Refrigerant pipe connecting Fan

Coil Unit (FCU) from room to
external Condensing Unit (CU)

Fan Coil
Unit (FCU)

Condensate
Drain
discharge
to Floor
Trap (FT)

Condensing Unit (CU) at aircon ledge

Figure: Air-conditioning and MV Routing

3.3.6 Town Gas

• Connection of town gas supply shall be able to withstand town gas supply pressure and free from leakage.
• Joints shall be treated as necessary to prevent corrosion.
• Concealment, if any, shall be subject to regulatory approval.

Prefabricated Prefinished Volumetric Construction 35

3.4 Compliance with Fire Safety Requirements
The design, construction and installation of the proposed PPVC system for building construction shall
comply with the fire safety requirements stipulated under the Fire Code.

3.4.1 Compliance of Fire Compartmentation

• To comply with fire resistance rating required for the elements of structure of the building.
• The typical compartment floor between floor levels shall comply with the required fire resistance rating in
accordance with the Fire Code requirements for the compartment floor which is an element of structure.
• The compartment walls segregating the dwelling units as well as segregating the dwelling units and
fire fighting lobby shall comply with the required fire resistance rating in accordance with the Fire
Code requirements.
• Provision of documentary proofs and detail drawings to illustrate compliance of Fire Code requirements
of the proposed system in terms of compartmentation, material usage, etc. is required.

Compartment wall
segregating dwelling units

Lift Lobby Lift Lobby

Compartment wall segregating the

dwelling units and fire fighting lobby

Figure: Example residential tower block plan – Compartment walls

36 Design for Manufacturing and Assembly (DfMA)

 Compartment
floor segregating
the dwelling
units

Figure: Example of 3D Modules – Compartment floors

3.4.2 Compliance of Use of Material

• Use of materials has to be considered to ensure the integrity of PPVC modules.

• To comply with the fire safety requirements for the use of plastics in building construction and the fire
safety requirements for incorporating services within fire-rated dry construction in buildings.
• The use of building products/materials/systems shall comply with the fire test performance requirements
stipulated in the fire safety guidelines for certification of regulated fire safety products/materials of the
Fire Code. Fire test performance reports from accredited test laboratories & Certificate of Conformity
(COCs) / Declaration of Compliance (DOC) for regulated fire safety products from Certification Bodies
(CBs) accredited by Singapore Accreditation Council (SAC) shall be provided for the proposed products/
materials/systems.
• If overseas accredited testing laboratory recognised by Singapore Accreditation Council (SAC) is engaged
to conduct the fire performance tests for the proposed products/materials/systems, the test performance
reports shall be certified by any of the accredited Certification Bodies (CBs) in Singapore before they can
be used for building construction in Singapore.
• To consider early engagement of the certification body and registered inspector (RI) to conduct factory
inspection at the overseas manufacturing plant for certification and conformity of regulated fire safety
products/materials/systems.

Prefabricated Prefinished Volumetric Construction 37

Chapter 4

PPVC Module Production

4.1 Reinforced Concrete (RC) PPVC Production
4.1.1 Mould Process

Moulds are fabricated in steel with comprehensive design to withstand the handling and production
process for the lifetime required in production. These moulds are three-dimensional and may be adjusted
to cater for several combinations of dimensions. The factors that influence the concept of mould design are
as follows:

Mould design
1

(Adjustable Mould)

Mould fabrication
2

Mould delivery to factory and setting up at factory

3

38 Design for Manufacturing and Assembly (DfMA)

4.1.2 Structural and MEP Works

Reinforced Concrete modules can be produced by integrating structures like column, beam, wall and slab as
a single module. The production process comprises of the following steps:

Reinforcement cage fabrication

1

Installation of MEP and other cast-in items

2

Inspection prior to concreting

3

Prefabricated Prefinished Volumetric Construction 39

 Concreting works
4

Upon completion of curing, demoulding and post-pour inspection

5

Demoulding and hoist up of the modules

6

40 Design for Manufacturing and Assembly (DfMA)

 Shifting / turning and storing the modules
7

Upon the completion of the shell,

there shall be a trial assembly
off-site to check the vertical and
horizontal alignments, as well as the
check on the continuity of the MEP
services. Water (hydrostatic) test and
air-pressure test in accordance with
PUB’s requirements shall be carried
out on all sanitary pipes prior to
Architectural works.

Prefabricated Prefinished Volumetric Construction 41

4.1.3 Architectural Finishing and MEP Works

The architectural works shall be executed under the sheltered environment, by trained specific trades off-
site. The works shall comprise the following in the sequence of execution and on levelled platform.

MEP Installations

Wall Tiling

Cabinets
Sanitary Fixtures

Waterproofing and
Floor Tiling
Window Switches Wall Plastering Door
and Glazing and Power or Skim Coat Frame
Installation Points

Lightweight Panel Plastering, Skim

Painting Coat and Painting

False Ceiling

Railing Installation

Wardrobe

Floor Finishes Installation

and Skirting

42 Design for Manufacturing and Assembly (DfMA)

 Levelling the module, and checking for alignment and dimensions
1

Installation of light weight panels

2

MEP installation
3

Testing of MEP installations

4

Prefabricated Prefinished Volumetric Construction 43

 Structural Ponding test, waterproofing application and waterponding test
5

Floor screeding works

6

Fixing of window frame and glazing

7

Installation of door frames

8

44 Design for Manufacturing and Assembly (DfMA)

 Wall tiles installation
9

Plastering and skim coating works

10

Floor finish installation

11

Floor finish installation

12

Prefabricated Prefinished Volumetric Construction 45

 Installation of bathroom/sanitary fixtures
13

Installation of wardrobe
14

Installation of cabinets
15

Completion of MEP piping and accessories

16

46 Design for Manufacturing and Assembly (DfMA)

 Installation of railing works
17

Installation of false ceiling

18

Painting works
19

Protection of the completed works

20

Prefabricated Prefinished Volumetric Construction 47

4.2 Steel PPVC Production
In order to ensure accuracy of the final product, special care must be given to each fabrication process,
starting from design and fabrication of 2D and 3D jigs, procurement and preparation of structural steel
member and the selection of the process, work sequence, method, machine and consumables used in the
welding work.

Whenever possible, customised welding robots could be used in place of manual welding to reduce the
reliance on manpower and to increase productivity.

Figure: Robotic Welding Machine

Photographs Courtesy of Tiong Seng Contractors Pte Ltd and Steeltech Industries Pte Ltd

4.2.1 2D and 3D Jigs

The jigs used in the fabrication work are designed and fabricated to withstand additional force caused by
heat transmitted between and within the steel sections to ensure the accuracy of the 2D frame and 3D shell
remain unchanged during and after welding work.

The total number of jigs required for each project is determined by the design and type of modules, the
fabrication schedule/rate and the flexibility of the jigs. It is different from project to project.

Photographs Courtesy of Moderna Homes Pte Ltd

48 Design for Manufacturing and Assembly (DfMA)

4.2.2 Fabrication Process

Validation of raw material against

Factory Production Certificate (FPC) and Mill Cert
1

Preparation and cutting of material

2

Engraving for ease of identification and validating of galvanised thickness

3

Prefabricated Prefinished Volumetric Construction 49

 Fitting and welding of steel members to 2D frame
4

Fitting and welding of 2D frame into 3D shell

5

QC check on welding quality

6

50 Design for Manufacturing and Assembly (DfMA)

 Trial stack to ensure overall dimension and accuracy
7

Installation of M&E piping/conduit

8

Installation of drywall - studs, insulation, fireboard and/or plaster board

9

Prefabricated Prefinished Volumetric Construction 51

 QC check - on drywall quality
10

Waterproofing and water ponding test

11

Tiling work – for floor and wall

12

52 Design for Manufacturing and Assembly (DfMA)

 QC check and tile protection
13

Installation of window frame, glazing and water tightness test

14

Installation of window grille and door frame

15

Prefabricated Prefinished Volumetric Construction 53

 Installation of external cladding and ledge
16

Painting - basecoat, 1st coat and 2nd coat

17

Installation of wardrobe and fixing of plumbing/sanitary ware

18

54 Design for Manufacturing and Assembly (DfMA)

 Protection of modules (from water ingress) before delivery
19

Delivery and installation of PPVC modules

20

Modules installed on site

21

Photographs Courtesy of Office of Photographs Courtesy of

Development & Facilities Management, NorthernOne Development Pte Ltd
Nanyang Technological University and Surbana Jurong Pte Ltd

Prefabricated Prefinished Volumetric Construction 55

Chapter 5

Protection, Transportation and Lifting

5.1 Transportation Plan
In order to ensure the quality of the PPVC
modules, it is important to set up a comprehensive
Transportation Plan to analyse and mitigate issues
brought about during deliveries. This is to avoid
potential damage to the module in long distance
travel. The Transportation Plan shall comply with
LTA’s traffic regulatory requirements.

At the same time, Just-In-Time (JIT) delivery concept

shall be studied with the transportation issues in
order to ensure the following:
1. The right time of delivery,
2. Manage site storage,
3. Optimise crane usage,
4. Minimise the hoist and handling of PPVC

Overseas Factory

ICA Checkpoint

Delivery to Site
for Installation

56 Design for Manufacturing and Assembly (DfMA)

5.2 Packaging, Protection and Labelling
• Packaging of the finished PPVC product shall be controlled and inspected to ensure conformance with
the specified and/or contracted requirements.
• The protection to completed PPVC modules shall be provided to the extent necessary to prevent potential
damage, deformation or deterioration of the installed finishing components and/or to the structure
while in transit or during unloading at project site. This includes the provision of appropriate protection
sheet to internal finishes and to the external surface of structures.
• All finished PPVC modules shall have the manufacturer’s label and installed for identification.

5.3 Module Cover (Temporary or Permanent)

• Module cover shall be manufactured according to size and design requirements (applicable to Reinforced
Concrete PPVC).
• Temporary or permanent covering method depends on the project specification. An approval should be
sought prior to installation.
• Installation of cover shall be inspected and approved prior to any handling for delivery.

Temporary safety
railings

Temporary or
permanent roofing

Completed module

Prefabricated Prefinished Volumetric Construction 57

Chapter 6

Construction and Project Management

6.1 Location of The Project and Adjacent Areas
• The condition of the roads surrounding the project must be able to accommodate the weight and size
of the PPVC module delivery.

6.2 Access and Traffic Management for Trailers with Heavy Cargo
• The access to and within the site must be able to accommodate trailers with heavy cargo. Slopes and
undulating terrain might prove to be a challenge for heavy vehicles. The turning radiuses of the trailers
has to be considered during the planning stage of the site to avoid choking of vehicle access.
• Trailers with heavy cargo pose potential hazards upon entering while navigating the site. Traffic controller
has to be employed to ensure smooth traffic management within the site.

58 Design for Manufacturing and Assembly (DfMA)

6.3 Consideration of Just-In-Time (JIT) Operation
• Unlike conventional precast, PPVC modules are unable to be stored on site. Therefore, a Just in Time (JIT)
installation could prove to be efficient and productive. The rate of installation has to be determined for
a smoother JIT operation.
• Precast supplier can further employ systems such as Traffic Monitoring and GPS for Prime Movers to
better facilitate deliveries. This will in turn make JIT operation smoother and more predictable.
• It is advisable to have space for unloading and storage in the event where JIT installation is not possible,
e.g. during inclement weather, etc.

Prefabricated Prefinished Volumetric Construction 59

6.4 Types of Cranes
• The crane employed must be able to handle the weight of the PPVC modules, but at the same time be
able to provide enough coverage for the intended block.
• Contractors shall seek approval from the relevant authorities on the maximum allowable AMSL clearance
for erection of cranes.

60 Design for Manufacturing and Assembly (DfMA)

6.5 Safety

A comprehensive risk assessment shall be A comprehensive Fall Prevention Plan with Safe
established to identify all potential hazards. Work Procedure and appropriate control measures
Appropriate control measures must then be set have to be established. Control measures such as
up, communicated and implemented before the safety barricades shall be provided for all open
commencement of works. sides where a person may fall. Such barricades
can only be removed during installation when
the precast component is hoisted near its
designated position.

All workers who are carrying out work at height All lifting gears and equipment are to be
shall be provided with the appropriate Personal in serviceable condition. Checks have to be
Protective Equipment such as a personal fall arrest conducted by Accredited Checkers periodically
system. They shall be trained in the proper use of to ensure workers are working with safe and
the system and ensure that the system is in place functional equipment.
at all times.

Prefabricated Prefinished Volumetric Construction 61

Chapter 7

Installation
7.1 Access and Egress
• An access has to be provided for workers to move in and out during an installation. Any open area
will have to be covered with safety barricade to prevent any worker from falling from height. A clearly
demarcated egress has to be provided as well to allow workers to exit the work area in the case of
an emergency.

7.2 Vertical and Horizontal Alignments

• Special attention has to be given to the alignments during installation. The method statement for
installation should indicate clearly how proper alignments can be achieved to prevent any abortive works.
• Improper vertical and horizontal alignments cause external gaps which require additional touch-up
work such as hacking and plastering. Windows and/or any external fixtures will look slanted as well.

Vertical Misalignment Horizontal Misalignment

62 Design for Manufacturing and Assembly (DfMA)

• MEP services including lightning protection system, sanitary and rain water discharge system etc. require
proper vertical continuity connection. Installation of P-trap, S-trap if required, shall not impact finishes
done up in a factory. If vertical concealed shaft is provided, space for installation works shall be allocated
to facilitate vertical connection works.

• For MEP services that require installation works horizontally crossing modules, (including wiring,
pressurized pipeworks, gradient pipeworks), the method of connection, if required, shall not compromise
the level of continuity. All point of connections shall be properly secured by proper support. Method of
connections shall not compromise the gradient required for gradient-pipeworks. Proper protection to
finishes to be provided if hot work is required for connections. Installation works shall be done via the
space allocated for installation works.

7.3 Sequencing of the Modules Installation

• It will be useful to work out the installation sequence of components to best maximise productivity
during installation. E.g. it might be easier to install modules facing the external and work towards the
inner modules.

7.4 Safety
• Workers are prone to high-risk activities such as Lifting Operation and Fall from Height. Proper safety
equipments are be provided to ensure the well being of the workers are taken care of.

• Safety documents such as Risk Assessment and Safe Work Procedure are to be submitted and vetted
thoroughly by the site safety officer. Safety Instruments are to be checked regularly. Daily Permit to work
has to be submitted dutifully to ensure workers work in a safe environment.

Prefabricated Prefinished Volumetric Construction 63

Chapter 8

Critical Inspection and Quality Check

8.1 Quality Checks
8.1.1 Reinforced Concrete PPVC

QC inspection on mould dimension, squareness, verticality and cleanliness

Reinforcement Installation and QC Inspection

Cast in Item Installation and QC Inspection

QC Check on Mould Assembly and Closing of Mould

QC inspection on concrete

Casting

64 Design for Manufacturing and Assembly (DfMA)

8.1.2 Steel PPVC

QC inspection on Welding Procedure and Specification (WPS),

Welding Procedure Qualification Record (WPQR), Welder Certificate,
Welding Consumables and all other related items.

QC inspection on the dimension and accuracy of 2D and 3D jigs

Respective steel members are placed inside a 2D jig, welded to

form 2D frame & QC Inspection

Respective 2D frames are placed inside a 3D jig, welded to

form a 3D shell & QC Inspection

Trial stacking (according to the actual position) at factory

to ensure the accuracy of the steel shell

Proceed to Architectural Work

Prefabricated Prefinished Volumetric Construction 65

 Bulging
8.2 Structural Works
The modules shall be pre-assembled before proceeding with the following inspection and finishing works.

LEVEL AND ALIGNMENT VERTICALITY BULGING

Location of Cast in items
The
Position of level and alignment shall Finished module shall maintain No bulging of all structural
Continuity Twisting of Module

remain within the tolerance its verticality not greater than the elements, as this will decrease
limits. stipulated tolerance for PPVC. the stability of the structures.

POSITION OF CONTINUITY LOCATION OF CAST IN ITEMS TWISTING OF MODULES

It is significant to maintain The location of the cast-in items All precast modules shall not
the position of reinforcement shall be checked and verified be greater than the allowable
continuity to increase the speed prior to casting to avoid a tolerance of all corners. This
MEP opening
of installation of precast module.
Structuralredo/rectify.
opening position and Dimension will apply to the installation
with regards to level, alignment
and verticality.

FIRE AND CORROSION STRUCTURAL OPENING MEP OPENING

PROTECTION POSITION AND DIMENSION Shall be larger than the actual
Passive fire protection layer and This will not be less than the size of the pipes.
corrosion protection layer for all actual dimension of doors,
structure steel members must be windows and etc.
check and confirm to ensure the
compliance to the code.

66 Design for Manufacturing and Assembly (DfMA)

 8.3 MEP Works Pressure test
Cable continuity test

WATER TIGHTNESS TEST PRESSURE TEST CABLE CONTINUITY TEST

Earthing megger test Electrical phase check
To ensure that pipe works are To ensure no leakage forleakageShall
Shaft be carried out to ensure
inspection

water-tight before and after the pressurised pipe works. cable and wiring condition.
architectural finishing works.

EARTHING MEGGER TEST ELECTRICAL PHASE CHECK SHAFT LEAKAGE

To be carried out after module Required to ensure load is INSPECTION
is completed to check on the distributed in accordance to To be carried out in conjunction
continuity of conductors for design among phases. with water-tightness test of
lightning protection. vertical pipe shaft.

Prefabricated Prefinished Volumetric Construction 67

8.4 Architectural Works

VERTICAL AND HORIZONTAL ALIGNMENTS

Shall incorporate from the given 1 meter datum and
offset line before finishing works.

Figure: Alignment verification.

LEVELLING
To ensure that the module is levelled and set before
the start of the finishing works.

Figure: Levelling of module

LIGHTWEIGHT PANEL INSTALLATION

AND QC CHECK
This will be installed as per the approved materials
and shop drawing. Adhere to approved method
statement to ensure that the execution falls within
the acceptable tolerance.

Figure: Lightweight Panel Installation

68 Design for Manufacturing and Assembly (DfMA)

 WATERPROOFING APPLICATION
AND QC CHECK
Application of waterproofing shall be carried out
by a qualified waterproofing installer. To adhere to
approved materials and method statement to ensure
that the waterproofing are installed accordingly.

Figure: Waterproofing Application

WATER PONDING TEST

Shall comply with the approved method statement.

Figure: Water Ponding Test

TILING INSTALLATION AND QC CHECK

All materials and method statement as well as
shop drawing shall be approved by the relevant
consultant/s. It is important to check the batch
delivery to control the tonality of the tile. Only a
qualified tiler can install the tile.

Figure: QC Check on Tiling

Prefabricated Prefinished Volumetric Construction 69

 PULL- OUT TEST
This will carried out by an accredited laboratory.

Figure: Alignment verification.

SPRAY TEST
Shall comply with the approved method statement.

Figure: Spray Test

SKIM COATING APPLICATION AND QC CHECK

All materials as well as the method statement
recommended by the manufacturer shall
be approved.

Figure Skim Coat Application

FLOOR FINISHES QC CHECK

All materials and method statement and shop
drawing shall be approved by the relevant
consultant/s.

All materials and method statement shall be

approved by the relevant consultant/s.

Figure: Floor finishes Installation

70 Design for Manufacturing and Assembly (DfMA)

 KITCHEN AND SANITARY WARE
INSTALLATION AND QC CHECK
All materials, shop drawings and method statement
shall be approved by the relevant consultant/s.

Figure: WC Installation

DOOR AND WINDOW INSTALLATION AND

INSPECTION
All materials, method statements and shop drawings
shall be approved by the relevant consultant/s.

Figure: QC check on Window Installation

RAILING INSTALLATION AND INSPECTION

All materials, method statements and shop drawings
shall be approved by the relevant consultant/s.

Figure: Railing Installation

PAINTING APPLICATION AND INSPECTION

All materials and method statement shall be
approved by the relevant consultant/s.

Figure: Painting Application

Prefabricated Prefinished Volumetric Construction 71

Chapter 9

Maintenance, Replacement and

Renovation
9.1 Maintenance and Renovation
It is essential to exercise care during renovation to prevent damage to the unit. The trained renovator
engaged for the project should use the appropriate tools and follow the instructions in the homeowner
user manual.

• The renovator should be trained.

• It is important to use appropriate tools for renovation works.
• Exercise due care when renovating, replacing tiles, etc. by referring to the homeowner user manual.

72 Design for Manufacturing and Assembly (DfMA)

9.1.1 Homeowner User Manual

Besides engaging a trained renovation contractor, homeowners should have a ready reference of the PPVC
system used in the unit. It is good practice for developers/builders to provide a homeowner user manual
of the PPVC upon completion of the project. The homeowner and subsequent buyers of the unit should
obtain a copy of the homeowner user manual after taking over the unit and follow the recommendations
on maintenance and renovation to PPVC units provided in the manual.

The information in the homeowner user manual could include (but not limited to) the following:

GENERAL INFORMATION ON PPVC

(i) Introduction to the PPVC installed
(ii) Safety notices
(iii) Instruction for use

STRUCTURE OF THE PPVC

(i) Floor
(ii) Wall
(iii) Ceiling
(iv) Water piping
(v) Sanitary discharge pipe/vertical soil stack
(vi) Electrical conduits

LAYOUT OF THE PPVC

(i) General layout
(ii) Waterproofing layout
(iii) Locations of concealed services
(iv) Location of access panel Figure: Example of unit floor plan
(v) Location of the manufacturer’s label

CLEANING AND MAINTENANCE ADVICE

(i) Internal fittings, tiles and accessories
(ii) Floor trap
(iii) Ceiling access panels

ALTERATION, REPAIR AND

REPLACEMENT WORKS
(i) Replacement of accessories/installation
of additional fittings
(ii) Availability and supply of spare parts
(iii) Instructions for drilling and fixing
(iv) Instructions for tile replacement
(v) Instructions for grab bars installation Figure: Example of reflected ceiling plan

Prefabricated Prefinished Volumetric Construction 73

Chapter 10

Regulations
10.1 List of Regulators

S/N Agency Regulation

Code of Practice on Buildability 2017
Building CP82, BCA’s Good Industry Practice Guide
1 Construction
Authority (BCA) Technical Requirements for Storey Shelters 2015
Technical Requirements for Household Shelters 2012
Rule 99 of Road Traffic Rules (OVM)
Land Transport
2
Authority (LTA) Rule 2010 Promulgated under the Road Traffic Act (OVM)

Fire Safety Act and Regulation ”Code of Practice for Fire Safety
Precaution in Buildings”
Singapore Civil
Fire Safety Requirements for the use of Plastic in Building
3 Defence Force
Construction, SCDF’s circular dated 1 Oct 2014.
(SCDF)
Permitting Services within Fire-Rated Dry Construction in Buildings,
SCDF’s circular dated 13 Nov 2014.
Code of Practice on Environmental Health, Singapore Standard SS593,
National COP on Pollution Control, Code of Practice on Sewerage and Sanitary
4 Environment Agency Works, Environmental Protection and Management Act, and their
(NEA) Regulations, including the Environmental Protection and Management
(Control of Noise at Construction Site) Regulation
Singapore Standard CP 48: Code of Practice for Water Services
1. Sewerage and Drainage Act
2. Sewerage and Drainage (Sanitary Works) Regulations
3. Code of Practice on Sewerage and Sanitary Works
4. Code of Practice on Surface Water Drainage
5. Public Utilities (Water Supply) Regulations
BS EN 1253-1, in event, if client preferences for shallow floor trap
Public Utilities (SFT) all relevant test shall comply with BS EN 1253-1 as follows:
5
Board (PUB) 1. Anti-Blockage Test
2. Water Tightness Test
3. Flow Rate Test
4. Resistance to water seal to pressure
5. Odour Tightness Test
6. Depth of water seal
7. Access for Cleaning
8. Side Inlet
Workplace Safety And Health Act 2014
Ministry of
6 WSH (Exemption) Order 2011
Manpower (MOM)
Workplace Safety and Health (Design for Safety) Regulation 2015

74 Design for Manufacturing and Assembly (DfMA)

10.2 Minimum Level of Off-Site Works for PPVC

Elements Minimum level of completion off-site

Floor finishes 80%

Wall finishes 100%

100% base coat,

Painting
only final coat is allowed on-site

Windows frames and glazing 100%

100%, only door leaves allowed

Doors
for on-site installation

100%, only doors are allowed

Wardrobes
for on-site installation

100%, only doors are allowed

Cabinets
for on-site installation

MEP including water and sanitary pipes, 100%, only equipment to allowed
electrical conduits and ducting for on-site installation

100%, only light fittings allowed

Electrical sockets and light switches
for on-site installation

*Source: Code Of Practice On Buildability , 2017 Edition

Prefabricated Prefinished Volumetric Construction 75

10.3 Building Innovation Panel (BIP) and
PPVC Manufacturer Accreditation Scheme (MAS)
To ensure quality and address potential downstream issues for local projects:
• PPVC suppliers are required to obtain In Principle Acceptance (IPA) from the Building Innovation
Panel (BIP).
• The acceptance framework consists of two parts (1) Evaluation of the PPVC system by the BIP (2)
Meeting the PPVC Manufacturer Accreditation Scheme (MAS) requirements.

PPVC Accreditation Programme

JOINTLY DEVELOPED BY

76 Design for Manufacturing and Assembly (DfMA)

10.4 Singapore Standards, Codes of Practice and Good Industry Practice
Guidebooks (References)
• CP 5: 1998 Code of Practice for Electrical Installations
• Code of Practice on Sewerage and Sanitary Works
• CP 48: 2005 Code of Practice for Water Services
• CP96: 2002 (2011) Code of Practice for Curtain Walls
• Code of Practice on Buildability 2017
• SS 608: 2015 Code of Practice for Gas Installation
• SS 555: 2010 Protection Against Lightning
• SS 553: 2009 Code of Practice for Air-conditioning and Mechanical Ventilation in Buildings
• SS 554: 2009 Code of Practice for Indoor Air Quality for Air-conditioned Buildings
• SS 212: 2007 Specification for Aluminium Alloy Windows
• SS 381: 1996 (2007) Materials and Performance Tests for Aluminium Curtain Walls
• EN1253-1 (shallow floor trap)
• In-built Bathrooms Performance Requirements
• Good Industry Practices Guide Book: Ceramic Tiling
• Good Industry Practices Guide Book: Marble and Granite Finishes
• Good Industry Practices Guide Book: Waterproofing for Internal Wet Areas
• Good Industry Practices Guide Book: Painting
• Good Industry Practices Guide Book: Timber Flooring
• Good Industry Practices Guide Book: Waterproofing for External Wall
• Good Industry Practices Guide Book: Aluminium Window
• Good Industry Practices Guide Book: Timber Doors
• Good Industry Practices Guide Book: Wardrobes and Kitchen Cabinets
• Good Industry Practices Guide Book: Precast Concrete Elements
• Good Industry Practices Guide Book: Drywall Internal Partition
• Good Industry Practices Guide Book: Design and Materials Selection (Vol 1)
• Good Industry Practices Guide Book: Design and Materials Selection (Vol 2)
• Design for Maintainability Checklist by BCA

Prefabricated Prefinished Volumetric Construction 77

10.5 Design for Safety
• PPVC supplier, designer, Qualified Person, Developer and Main Contractor are relevant stakeholders that
shall be involved in the DfS review.
• Design for safety reviews should be carried out upstream, e.g. during the BIP application or at the
concept and detailed design phases, to address risks that would manifest itself during:
1. the construction stage,
2. the building maintenance stage; and
3. the demolition phase.

Things to note:
• For onsite installation, please pay special attention to activities related to Lifting, Access/Egress and
Working at Height.
• The design should cater adequate provisions for safe PPVC building maintenance and repair.
• User/ installer manual should include safe demolition sequences and special precautions.
• PPVC suppliers/ designers shall control the design risks based on the Hierarchy of Control Measures.
PPE shall be adopted as a last resort.

WSHC DfS Guidelines WSH DfS Regulations

78 Design for Manufacturing and Assembly (DfMA)

Specific requirements related to the PPVC should be considered in the early design review stage.

10.5.1 Access/Egress

As part of the design review, the entire process of which the PPVC units are to be installed should be
reviewed. This should include how workers would gain access to and egress:
1. from the ground to the top of the modules loaded on a trailer;
2. from the ground to the top of the modules in the holding/ storage area;
3. from the working level to the top of a PPVC module that had just been installed;
4. from point A to point B of the same level of the installed PPVCs, or cast in-situ areas or working platforms.
5. from point A to point B of the different level of the installed PPVCs, or cast in-situ areas or
working platforms.

Such access provisions include the use of MEWP, mobile tower scaffolds with appropriate height, fixed
ladders with proper fixtures that are cast-in during the fabrication of the modules or use of permanent/
temporary staircase. If a vertical access ladder (see figure 2) is proposed, it should be secured in place at
its top & bottom and extended 1 meter above the landing. Such ladder will not be suitable if the user is
unable to maintain 3-points of contact. In general, a step platform ladder (see figure 3) would provide a
safer access and more stable work surface than the vertical access ladder or A-frame ladder. If the ladder
leads to a barricaded area, a proper access point should be catered for in the design.

(Fig. 2) vertical access ladder with both stiles tied. (Fig. 3) Step platform ladder (Mobile).

Prefabricated Prefinished Volumetric Construction 79

10.5.2 Choice Between Fall Prevention, Fall Restraint and Fall Arrest System

Before choosing a fall prevention or protection system, one should first consider elimination of working
at height.

ELIMINATION OF WORK AT HEIGHT

Always explore elimination first. Works that involved a risk of fall should be eliminated at design stage.
An example of PPVC risk elimination is shown below (e.g. A):

Example A: In the above figure, the designer had

proposed connection of the two high floor modules
using bolts, nuts and a link plate. As the connection
work can only be carried out externally from the
building façade, it would mean that workers will
have to extend their bodies out of the PPVC to reach
the connections thereby exposing themselves to a
risk of fall. After the review, the designer redesigned
the connections to be connected within the safety
of the PPVC unit and successfully eliminated the
falling from height risk related to the task entirely.

SUBSTITUTION OF A SAFER WORK-AT- HEIGHT METHOD

• If the risks cannot be eliminated by design, designers should explore safer work methods to mininise the
risk e.g. use of MEWP, scaffold or step platform ladder instead of A-frame ladder placed beside the PPVC.

ENGINEERING CONTROL – FALL PREVENTION

• Where workers are required to work on the top
of a module or at any location where there is risk
of fall, the open sides of the module or location
should be effectively barricaded or guarded
(Engineering Control measure). The connections
for the barricades or guardrails should be built-
in with the module where possible.
• Fall prevention system such as the use of
barricades is preferred over fall restraint and fall
arrest systems. Barricades provide a high degree
of protection once properly installed. When a
barricade is proposed, the design should meet
ACOP Working Safely at Heights
the requirements under the Approved Code of
Practice for Working Safely at Heights published
by WSHC. (See link below)

80 Design for Manufacturing and Assembly (DfMA)

PERSONAL PROTECTION EQUIPMENT ( PPE )
Where barricades or guardrails cannot be provided, anchorage points and/or lifelines should be provided
to ensure that workers are protected from falling from height. Anchorage points, anchorage lines, safety
harness etc. should be pre-planned for, taking into consideration the zone of which the workers would
need to operate for rigging / unrigging operations and for other works, e.g. grouting works at the top of the
module or at working level.
 
In general, there are two types of fall protection or prevention systems: Fall Restraint and Fall Arrest, of
which the former is preferred over the latter.

Fall Restraint Systems prevent a person from falling and includes the use of:
i) Work-Positioning and
ii) Travel Restraint systems

Fall Arrest Systems protect a person after the person falls a certain distance by stopping the fall before the
person hit the surface below. It includes the use of:
i) Full body harness, shock absorber and Anchor
ii) Safety nets

Please also refer to the prevailing codes including SS 570, S541 and SS607.

Prefabricated Prefinished Volumetric Construction 81

10.5.3 Module Installation and Alignment

During the PPVC installation, it is important to avoid the need to align too many connecting bars as this
will increase the installation duration and the likelihood of installers being exposed to risks of crushing
and being caught-in-between objects. In the event of misalignment/ bent bars, there should be established
measures to ensure no worker shall go underneath the PPVC unit to realign the bars.

10.5.4 Useful Resources

WSH Council’s Website MOM’s Website WSHC-Approved COP WSH Act and
Regulations

82 Design for Manufacturing and Assembly (DfMA)

Appendix
Some PPVC Project References in Singapore (Completed and Ongoing)
A. Completed PPVC Project
1. NANYANG CRESCENT HOSTEL
• 4 blocks, 11 to 13 storeys
• Hostel rooms are built using PPVC
PPVC System
• 784 modules
• Steel PPVC frame with cement board floor base
Photographs Courtesy of Office of Development
& Facilities Management, Nanyang Technological
University for Nanyang Crescent & SAA Architects
Pte Ltd
2. WOODLANDS NURSING HOME
• 9 storeys
PPVC System
• 343 modules
• Steel PPVC system with concrete floor base
Photograph Courtesy of Dragages (Singapore) Pte Ltd

3. NTU NORTH HILL HOSTEL

• 8 blocks, 13 storeys
• 1,580 hostel rooms, 66 apartments
PPVC System
• 1,200 modules
• Steel PPVC frame
• Cement board floor for hostel rooms
• Lightweight concrete floor for staff apartments
Photographs Courtesy of Office of Development
and Facilities Management, Nanyang Technological
University for Nanyang Crescent

4. CROWNE PLAZA HOTEL EXTENSION

• 10-storey hotel project with creative
facade design
• Single block
• 243 guest rooms
PPVC System
• 252 modules
• Steel PPVC with concrete floor base
Photographs Courtesy of OUE Limited

Prefabricated Prefinished Volumetric Construction 83

B. On-going (under construction) Projects
1. BROWNSTONE EXECUTIVE CONDOMINIUM
AT CANBERRA DRIVE
• 8 blocks, 10 & 12 storeys
• 638 residential units
PPVC System
• 4,436 concrete volumetric modules
• Concrete PPVC
Photographs Courtesy of Canvey Developments Pte
Ltd (a subsidiary of City Developments Limited) and
TID Pte Ltd

2. WISTERIA AT YISHUN AVENUE 4 –

COMMERCIAL AND CONDOMINIUM
DEVELOPMENT
• 3 blocks of 12-storey mixed development
• First 3 floors are commercial and the rest are
apartment units
• A total of 216 apartment units
PPVC System
• 756 modules
• Steel PPVC frame with concrete floor base
Photographs Courtesy of NorthernOne Development
Pte Ltd and Surbana Jurong Pte Ltd

3. CLEMENT CANOPY CONDOMINIUM AT

CLEMENTI AVE 1
• 40-storey flat condominium development
• 505 apartment units
PPVC System
• 1,866 modules
• Concrete PPVC system
Photographs Courtesy of Site, Credit to Dragages
(Singapore) Pte Ltd, Artist Impression to UOL
Group Limited

84 Design for Manufacturing and Assembly (DfMA)