1. INTRODUCTION

In Hong Kong, on behalf of our client Leighton Gammon JV we designed and operated the first ever project specific rebar fabrication facility commissioned and operated in Hong Kong , we also provided our Rebar Detailing Service & Rebar Management Software.

2. KEY FACTS

Total Requirement: 150,0000 tonnes

Schedule: 24 months

Peak Capacity: 10,000 tonnes per month

3. FACTORY OVERVIEW

  • A capacity of 300MT/day; 7am to 7pm
  • Buffer storage of 2,000MT
  • Internal cut and bend storage = 600MT
  • All cut and bend dimensions are computer controlled
  • Bending and crank bars accuracy of 10mm
  • Capable of cutting 2 x T50 at once
  • Threading & Coupling are included in the production lines

4. CHALLENGES FACED

  • Traditional Measure Provisional Rebar Qty including Coupler requirement is not accurate and is usually understated as GA and laps and anchoring lengths as per actual site condition are not considered
  • Steel Procurement is difficult due to incorrect or lack of required detail coming from the Measure
  • Shop Drawings & BBS are not prepared for engineering approval before fabrication as they are in most other countries
  • BBS are prepared manually handwritten on paper or in Excel, effective management is difficult to achieve
  • Cut and Bend activities are performed in multiple locations on-site and off-site fabrication yard
  • Wastage figure is uncertain and achieving this fixed % of wastage can lead to increased steel fixed in the structure

5. BENEFITS – REBAR DETAILING

  • Accurate Measure of Rebar Quantities including diameter & Length
  • Ability to reduce steel cost by purchasing correct Diameters in Advance
  • Accurate Lengths will enable special lengths procurement reducing steel qty and wastage
  • Creation of digital Detailer drawings from GA & IFC drawings
  • Fast implementation of revisions by editing 1st Issue of Digital Detailer drawings
  • Automatic creation of BBS from drawing to ensure no risk of human error
  • Have one accurate source of information for measurement and construction
  • Direct integration of BBS into Cloud for downstream management







6. BENEFITS – REBAR MANAGEMENT

  • Full management & quantification of Stock Rebar received using QR Codes
  • Digital sustainability & Carbon Accounting
  • Recording of actual pictures of physical steel including loading and off loading
  • Revision and change Management, identification & quantification
  • Full traceability of ordered, delivered and fixed rebar via QR Code with GPS
  • Reuse of redundant rebar
  • Real Time Progress Monitoring of all Rebar production Activities via QR Codes
  • Complete Transparency and Visibility of Rebar information (QTY, location and status) throughout the Project Timeline from Detailing, Site Management, Fabrication and Fixing.
  • Full transparency on the rebar Quantity, Tender, IFC, As Built procured
  • Downloading optimized cutting lists to production machines
  • Transmission of precise lengths and bending dimensions to computerized bending equipment via QR codes