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Background
The industrialised building system (IBS) can be generally interpreted as in which all
building components are mass produced either in a factory or at site factory
according to specifications with standardise shapes and dimensions and transported
to the construction projects site to be rearrange with certain standard to form a
building.
The development of industrialised building system (IBS) is not new in the
construction industry. The history of precast in UK housing dates from the mid
1900s, when this and other forms of industrialised (prefabricated) construction were
used to address the problem of widespread destruction of housing stock during the
Second World War.
In the United States, the use of precast in the construction industry began in the
construction of prefabricated steel house by General House in 1930. However the
early efforts of rationalising and implementation faded quickly due to price in
competitiveness, high capital and inconsistent local codes. The use of precast
increased sharply after the Second World War due to the need to resolve critical
shortage of houses.
In Malaysia, the implementation of precast concept by using precast concrete
building were introduced in Malaysia in 1966 when the government launched two
pilot projects for precast housing which involves the construction of Tuanku Abdul
Rahman Flats in Kuala Lumpur and the Rifle Range Road Flats in Penang. Both
projects were the first time whereby precast elements were used to construct mass
houses. Later, PerbadananKemajuanNegeri Johor (PKNS) import the precast
concrete technology from Germany for the construction ranging from low cost
housing to luxurious housing such as bungalows and semidetached.
Today, many private companies in Malaysia have teamed up with foreign experts
from Australia, Netherlands, United States and Japan to offer precast solutions to
their projects. Numerous construction projects have utilized the precast components
especially to meet the requirement of time constraint and with high accuracy and
quality. The precast components are mainly use in the construction of schools,
colleges, quarters, apartments, hospitals, roads, port and other infrastructures. Even
so, the usage of precast in building in Malaysia is still low as compared to developed
countries such as Japan, United States and Europe. From a survey conducted by
Construction Industry Development Board (CIDB) Malaysia, the level of usage of IBS
in the local construction industry is at 15% based on the IBS Survey 2003. The main
barriers that impede the growth of IBS are the resistance from the parties involved in
the construction. The local authorities are generally unwilling to make changes in
local building regulations that need a lot of time, works and cost to establish the
legislative, structural planning and economic conditions for industrial development.
The developers have to plan a larger project scheme in order to reduce the costs of
houses for economic viability. The contractor will relatively play less important role
because most of the responsibilities will be taken over by the precast manufacturer.
Furthermore, the subcontractors who rely on labour will be out of business due to the
fact that prefabrication will reduce the number of workers and replace them with
machines.
Currently, the Industrial Building System (IBS) in Malaysia has gradually widely used
as a modern method of construction. As an example, the Industrial Building System
(IBS) has been applied in several projects such as Kuala Lumpur International
Airport (KLIA), government quarters in Putrajaya, KL Sentral, Light Rail Transit (LRT)
and Bukit Jalil Sport Complex. Besides, Industrialised Building System (IBS) Centre
which is located at Jalan Chan Sow Lin, Cheras, Kuala Lumpur was established to
help on the evolment of the system. The implementation of Industrialised Building
System (IBS) in this country will help to reduce the entrance of foreign labor and to
expedite the progress of the construction.
There are five type of IBS generally used in construction:
1) Pre-cast Concrete Framing , Panel and Box System
2)
3)
4)
5)
HISTORY
In Malaysia, the history of industrialized Building System can be linked back to the
year 1963, where then, the government sent an architect from JabatanKerja Raya
(Public Works Department ) to Europe to learn more on industrialized buildings. The
housing industry has started experimenting with industrialized construction in the late
1960s with construction of two pilot projects of high rise low cost flats 3009 units of
flats in JalanPekeliling, Kuala Lumpur in 1966, and 3741 units of flats in Jalan
Padang Tembok, Pulau Pinang in 1967.
LRT Station
Pekeliling Flat
KLCC
KL Tower
IBS CLASSIFICATION
Generally, there are four types of building systems currently available in Malaysia
according to BadirRazali building system classification (Badir et al. 1998), namely
conventional, cast in-situ, prefabricated and composite building systems is shown in
Figure 1. Each building system is represented by its respective construction method
which is further characterised by its construction technology, functional and
geometrical configuration. Warszawski (1999) asserted that the building system
Production Facility:
The initial capital investment for setting up a permanent factory is relatively
expensive. Plant, equipment, skilled worker, management resources need to be
acquired before production can be commenced. Such huge investment can only be
breakeven if there is sufficiently high demand for the products. On the other hand, a
temporary casting yard or factory can be established at the project site in order to
minimize the transportation costs (Peng, 1986).
Transportation:
It is found that casting a large panel system can reduce labour cost up to 30 percent.
However, these cost savings are partly offset by the transportation costs. The
transportation of large panels is also subject to the road department and relevant
authorities (Peng, 1986).
Equipment at site:
For the purpose of erecting and assembling pre-cast panel into their position, heavy
crane is required especially for multi-story building. It is therefore important to
incorporate this additional cost when adopting a pre-fabrication system (Warszawski,
1999).
TYPE OF IBS
intensive marketing strategy by pre-caster to enlighten the client and designer the
potential benefit of the system in term of economic and noneconomic aspect.
Following the approach classified in the sixties as closed building system first a
project is designed and secondly subdivided into a number of building parts which is
will be produced especially for that project. In all case a lot of component are bought
on the market, therefore one should take care that certain dimension of the selfproduced building part fit with these other component, like an example, an apartment
block is divided during the design process into concrete wall and floor plates. These
concrete element are designed in such a way that the connection s between them
are possible. At the same time one should take care that the opening in the wall
element are coordinated with the window or doors one wants to use. Also the
sanitary equipment should be fit.
The main objective is to introduce the new concept system of Open building system
(OBS) in 2010, its the long term and systematic approach toward a positive
development of building industry. The OBS not only reengineer our construction
process such as supply chain, trade, design and other, but it transform the way of
doing the business in construction. Its allow opened supply of IBS where the
construction can bid the lower price with other company. Its stronger recommend to
allow the manufacture and assembler to enter the market, thus its reducing the price
of IBS component. The OBS open the chance of new business and built the new
company that more small and medium for Bumiputera to able produce construction
components.
Open building system also give a value to the customer or client with provide the
aesthetical, the practical selection and flexibility for the construction product market
since the supplier will only be motivated to invest in new product and innovation
solution if they can fore see enough sale. Local technologies on IBS component
such as in lightweight components and interlocking blocks can be fully utilized. OBS
allows at some points, customers and house buyers to be involved in design, trough
selection of building components at the onset of the project. The adoption of the
OBS together with fully utilization of IBS will greatly benefit the building industry as it
increases
the
production
capacity,
lower
manpower
requirement,
shorten
construction time, improve quality and in the long run bring down the overall building
cost.
The following condition must be fulfilled like it must be possible develop different
OBS. Due to the general rules governing those system concerning dimensional coordination, compatibility of performance) the decision to choose one specific OBS
can be postponed during the design process as long as necessary in a specific
situation. Like an example during the design process on has decided not to use a
bearing wall structure but a skeleton. Of course at the moment system making use a
bearing wall are exclude but the competition is open between system based on
concrete or steel, between column and beam system and portal frame. The same
building parts and the Open Building Sub system can be integrated in as many
different OBS as possible. The building part of different OBS can be exchange as
much as possible between such systems,
The concept Open Industrialization is not only incorporating prefabrication, but also
rationalized traditional method like system for in situ shuttering, system for
rationalized bricklaying.
Industry through the government bodies such as CIDB and SIRIM need to build or
develop with the standard Malaysia for the component of IBS. Its important because
two prefabricated part only fit on the building site if their dimension and the joint used
in closed system protected by patent. They are specifically design to fit the precaster prefabricated component and it is not supporting holistic concept of openness
in OBS. Through their research by CIDB, construction research institute of Malaysia
(CREAM) has been collaborated with Public work department (PWD) and also from
the University of Nottingham to see the strength, stiffness, ductility and stability of the
connection. OBS able to target the achievement for the market because the
customer will like the aesthetical and the design space of OBS system.
Marketing OBS concept to this target group will give a huge and profitable market
since the supplier will only be motivated to invest in new products and innovation
solution if they can foresee enough sales. Educate the customers to be more
involved in design stage is the way forward to promote OBS. Customer can choose
their building materials at the onset of housing development. This can create good
marketing gimmick to developers in order to attract homebuyers. Developers, then
can play their role to advice designers to design according to Modular Coordination
(MC) and based on available IBS components in the market. Then, the contractors
will pay the role of coordinating the installation of components according to
customers wish. Based on IBS Roadmap, CIDB will publish OBS Roadmap,
introduce OBS Steering Committee, to conduct OBS international seminar, publish
OBS catalogue and to use OBS as a main criteria to judge the contender for
Malaysian Construction Industry Excellent Award (MCIEA).
Figure 2.1
IBS CHARACTERISTICS
2) High number of foreign labor to be employed to do the hand jobs. With the
implementation of Industrialised Building System (IBS), the number of
foreign labor and the cost of the construction project can be reduced.
3) The economical forces can be one of the reasons why the Industrialised
Building System (IBS) is so important to our country. This factor may affect
the organizational of the clients and also the construction progress.
4) Benefits to adopters in term of cost and time certainty, attaining better
construction quality and productivity, reducing risk related to occupational
safety and health, alleviating issue on skilled workers and dependency on
manual foreign labor and achieving ultimate goal of reducing overall cost
of construction (Construction Research Institute of Malaysia, 2009).
ISO 9001:2015
ISO 9001:2015 sets out the criteria for a quality management system and is the only
standard in the family that can be certified to (although this is not a requirement). It
can be used by any organization, large or small, regardless of its field of activity. In
fact, there are over one million companies and organizations in over 170 countries
certified to ISO 9001.
This standard is based on a number of quality management principles including a
strong customer focus, the motivation and implication of top management, the
process approach and continual improvement. Using ISO 9001:2015 helps ensure
that customers get consistent, good quality products and services, which in turn
brings many business benefits.
drive the construction success as well as the problems and challenges around it
(Gibb &Isack, 2001).
However, the fragmentation and adversarial relationships among players in the IBS
supply chain has been identified as the main hindrance of the IBS construction
project delivery. Difficult to integrate and establishing integration between IBS supply
chain is attributed to the variety of professions and skills involved in the project
delivery procurement practices (Faizul, 2006) the challenges in achieving successful
delivery of IBS projects would be looking at encouraging integration through the
supply chain integration
Open System:
Supply chain that been use under this system are been made by use several
manufacturer company. Each component of construction are been made by different
manufacturer or supplier. There are several characteristic to be noticed before make
an order such as quality, quantity, market price, extra service location, ability and
potential. These things is very important to maximize the advantages of open
system. This type of system could provide the good challenges between the
manufacturers.
Closed System:
While, supply chain that been use under this type are more uniform and arranged
because all those building component that involved in construction are been
prefabricated under one manufacturer. When it been prepare and plan by one
manufacturer, other works are become easier and smooth. The transportation cost
and time could be reduce to they are under same company. Besides that, that
payment are also become fast.
1. Levels:
Specific spheres of control in the built environment. The built environment can be
seen as having an hierarchical structure in which higher levels serve as the setting
and context in which lower levels operate. As such, higher levels
exercise dominance over lower levels, while lower levels are dependant on higherlevel structures. Examples of levels include urban design and architecture, or base
building and fit-out.
2. Base building:
The part of a multi-tenant building that directly serves and affects all occupants. In
conventional North American practice, base buildings are constructed by speculative
office building developers, leaving choice and responsibility for the reminder of the
buildingthe fit-out - to occupants. The base building normally includes the building's
primary structure; the building envelope (roof and facade) in whole or part; public
circulation and fire egress(lobbies, corridors, elevators and public stairs); and
primary mechanical and supply systems (electricity, heating and air
conditioning, telephone, water supply, drainage, gas, etc.) up to the point of contact
with individual occupant spaces. Base buildings provide serviced space for
occupancy; Supports is another term for base building.
3. Fit-out (tenant work):
The physical products and spaces controlled by the individual inhabitant or occupant
used to make habitable space in a base building. Fit-out can change without forcing
the base building to change.
4. Capacity:
The measurable quality of a base building to accommodate a range of variations
in floor plan and use within the constraints of a given base building. More generally,
capacity concerns the degree of Open Building freedom offered by a higher level to a
lower level.
Global movement:
1) CIDB/Government adopted this approach in IBS initiative
2) Globally accepted features :
1. Multi- suppliers
2. Flexible Layout (Past Occupation)
3. Prefabrication
4. Life cycle
5. Own fit-out/interior
6. Raised / flexible floor system
In Open Building System (OBS), a building can use two or more systems. It allows
openness to selects components supplier where everybody can bid to produce lower
price of components. Manufacturer and installer will look for cooperation models that
will create benefit for both. OBS also allows the precaster to produce a limited
number of elements with pre-determined range of product and at the same time
maintaining architectural aesthetic value. The cost of building components will be
reduced in the long run where plenty of options are available in the market. It also
permits hybrid application.
The key aspect of OBS is dimensional coordination to allow flexibility in form of
construction, and the capacity to deal with differences in dimension and tolerance. In
order to obtain an optimal result, a high degree of coordination must exist between
various relevant parties such as designer, manufacturer, owner, and contractor. This
is achieved through an integrated system in which all these functions are performed
under a unified authority. Therefore the subdivision of the building process needs to
reflect the lines of decision making and the definition of responsibilities between the
parties. This subdivision can then be translated into specifications for connections
between building parts.
Open Building System (OBS) was first promoted during the rebuilding years of postwar Netherlands. The rules for dimensions, positions and interfaces of components
are important elements of OBS.
marketing strategy to inspire customers and designers in the economic and noneconomic aspects of long-term potential benefits of the system.
ADVANTAGES:
1) Involves simple operations with a minimum of workers.
2) Construction of concrete buildings become more efficient.
3) Manual labour works can be reduced.
4) Better surface finishes.
5) Mass production of units.
6) Casting under cover.
EXAMPLE:
1) Tunnel forms.
2) Tilt up systems.
3) Beams moulding forms
4) Columns moulding forms
5) Metal deck.
STEEL FRAMING SYSTEMS
INTRODUCTION
Steel framing systems have always been the popular choice and used extensively in
the fast-track construction of skyscrapers. It is commonlyused with precast concrete
slabs or metal decks steel framing systems which comprise of steel columns and
beams. This system consisting cost-effective profiled cold-formed channels and
steel portal frame systems as alternatives to the heavier traditional hot-rolled
section.
ADVANTAGES:
1) Buildability.
2) Simplicity of construction.
3) Greater construction speed.
EXAMPLE:
1) Light gauge steel framing.
2) Light steel trusses.
PREFABRICATED TIMBER FRAMING SYSTEMS
INTRODUCTION
Timber frame system has their own niche market which is offering
designs from simple dwelling units to buildings requiring
interesting
EXAMPLE:
1) Timber building frames.
2) Timber roof trusses.
BLOCKWORK SYSTEMS
INTRODUCTION:
1) The tedious and time consuming traditional brick-laying tasks are greatly
simplified by the usage of these alternative method.
2) A walling unit of length, width or height greater than that specified for a
brick.
3) Height of a block shall not exceed either its length or six times its thickness.
TYPES OF BLOCKWORK SYSTEM:
1) Solid block.
2) Hollow block.
3) Aerated or cellular concrete block.
4) Interlocking hollow block.
ADVANTAGES:
1) Reduction in labour usage.
2) Speed of construction.
3) Superior properties such as thermal and sound insulation and also free
resistance.
EXAMPLE:
1) Concrete mansory units.
2) Lightweight concrete units.
as
well
as
other
relevant
labour-reducing
technologies.
conventional
method.
recently
completed
survey
conducted
by
foreignworkers to not more than 15 percent of thecountry, labour force in the next
five yearswould be an impetus for the local developers touse IBS. By using a
superior constructiontechnology that requires highly skilled workers,the dependence
on foreign workers wouldsignificantly be reduced.Most of the IBSs in Malaysia have
beenvery recently established in the early 90s.
Thissudden and very rapid growth in the number ofIBSs is in perfect tune and
harmony with thetremendous amount of emphasis for buildingconstruction activities
in the Malaysia SeventhFive-Year Plan. The results of the analysisreveal that the
systems originating from theUnited States are the largest in number in
theconstruction industry in Malaysia (25%),followed by those from Australia and
Germany(17% for each). In all the IBSs used inMalaysia, the locally produced
systems accountfor only 12%. Austria and the U.K. represent 8% and 4%,
respectively. The rest of the buildingsystems (17%) are originally from othercountries
such as Canada, France, Japan, andFinland.Several projects that used IBS can be
seenas follows. i) KLIA ii) Putrajaya Bridge iii)Petronas Twin Towers, iv) KL Sentral.
Even so, the usage of IBS in building isstill low. From a survey conducted by
CIDBMalaysia, the usage level of IBS in the localconstruction industry stands at only
15% (IBSSurvey 2003). The early efforts of theGovernment to encourage the use of
IBS in theconstruction sector has yet to garner a good response, and this sector is
still
practicing
conventional
construction
methods
that
have proven time and again to be wasteful,dangerous and messy. Relatively, the
lowlabour cost in this country is the root cause ofthe industry failing to reform and
beingcomplacent
with
the
current
be
disputed
level
that
to
be
The industry needs one fundamental planthat involves all the important aspects in
thisevolution process. In this respect, the IBSRoadmap 2003-2010 is formulated as
areference
for
all
parties
in
implementing
contractors, professional
bodies,
higher
learning
excellent thermal insulation for living and working areas above the underground
garages for example.
Durable
Wood wool is naturally durable. It has the same service life as the building in which it
is used. The wood wool panels are easily fit into a tight ceiling. The high impact
resistance of the wood wool surface ensures optimal protection against any physical
damage.
Eco friendly
In the production of wood wool use is made of environmentally friendly raw materials
and green energy. The packaging of the products has been optimized and production
waste is largely being recycled. With certified wood, Technology and the optimized
production process, the wood wool Insulation delivers guaranteed natural and
sustainable wood wool products. With good type of wood wool are selecting a
qualitative, sustainable solution.
POLYMER IMPREGNATED CONCRETE
Concrete has served as an excellent construction material for many years. However,
conventional concrete has the disadvantage of being susceptible to the ingress of
water. Presence of water inside the concrete frequently causes problems in concrete
structures. The problems, such as freeze-thaw, corrosion of reinforcing bars are
considered to be serious problems because they are progressive and finally lead to
the complete failure of the structure. Deterioration of concrete highway bridge decks
involves a number and interaction of variable such as loading pattern, material
characteristics, and
have
been
extensive
removed from the concrete prior to monomer application. After the pores of the
concrete are filled. With the monomer, polymerization of the monomer is completed
by means of radiation or the thermal catalytic process.
Polymer-concrete (PC) consists of aggregate and monomer mixed together and
polymerization of the monomer is completed after placement of the m1xture of
monomer and concrete.
Polymer-cement concrete (PCC) is a mixture of cement, water, aggregate, and
monomer. These materials, included the monomer; are mixed_ together and
polymerization is completed after placement.
Impressive strength
Tensile strength
Modulus of elasticity
Water permeability
Water adsorption
Resistance to abrasion
Durability
The freeze-thaw durability was increased by more than 360 %. The water
permeability and chemical resistance were reduced to negligible values. The water
absorption decreased by as much as 95 %. The compressive strength of high
pressure steam-cured concrete impregnated with glass forms and radiation
polymerized has been found to be as high as 27000psi, The tensile strength and
modulus of elasticity have been found to increase by 292 % and 80 %, respectively.
However, the reason for increased strength is not completely understood. The
possible explanations are:
1) The polymer acts as a random reinforcement.
2) The polymer increases the bond between the cement paste and the
aggregate.
3) The polymer repairs micro cracks in concrete.
4) The polymer penetrates and reinforces the microspores in concrete.
Partition wall
A partition wall is a wall that separates rooms, or divides a room. Partition walls are
usually not load-bearing. Partition walls are constructed of many materials, including
steel panels, bricks, blocks of clay, terra-cotta, concrete, or glass blocks. Generally
these are non-load bearing walls and therefore, their cross section is taken thin.
Purpose of Partition walls are to divide the floor area of the building and for privacy
purposes for the inhabitants of the building.
Advantages of Partition walls is that these walls can be easily constructed because
they are thin in cross section. These walls are light in weight as their cross section is
thin so they occupy less area of the floor.
1. Brick Partitions:
This may be constructed with plain bricks, reinforced bricks or bricks nogged.
This type of wall is similar to plain brick partition wall except that at every third or
fourth course, the bricks are reinforced with iron straps 25 to 28 mm wide and 1.6mm
thick. Mild steel bars 6mm spaced at every third course of wall may be used as a
substitute for iron straps.
light, and easy in construction and provide reasonable privacy and sound insulation.
The cost of maintenance of such partition is much more as glass is liable to break
when struck hard by anything. With the introduction of reinforced glass sheets, this
danger is greatly minimized. Three-ply glass and armour plate glass are some of the
varieties of sheet glass.
Partition walls construction in concrete, plain or reinforced may be cast in situ or built
from panels or blocks, precast wall in advance of the commencement of work.
Generally for cast in situ walls, 10 cm thick and below, the reinforcement consisting
of mild steel bars or B R C fabric is placed in the centre of the wall thickness.
Concrete mix usually adopted in the work is M15 (1:2:4). The wall is cast
monolithically with the intermediate columns so as to be rigid and stable both along
its length and height. In case of precast concrete partition walls, precast concrete
slab panels and special shaped concrete post are used. The slabs are generally 32
mm thick and are inserted in the grooves of the precast post and the joints are
subsequently filled with mortar.
Metal lath and plaster when properly laid forms a reinforced wall which is thin,
strong, durable and is considerably fire resistant. The metal lath is available in
variety of patterns and it generally requires a framework of steel or timber for the
purpose of fixing it in position. In case of partition walls with steel frames, lath is
generally tied by galvanized iron wire to mild steel bars or channels spaced 15 to 30
cm apart. The latter is fixed on one side and the plaster is applied on both sides of
the lath. This type of partition wall may be 5 to 7.6 cm in thickness.
In order to achieve improved insulation against heat and sound, metal lath and
plaster partition walls can also be made with a cavity between the wall thickness.
This type of hollow partition wall is constructed by fixing the metal lath on both sides
of specially shaped steel channels spaced at 30 to 45 cm apart. Depending upon the
width of cavity desired, the channels are generally 3 to 10cm deep.
7. Timber partitions:
This type of partition walls consists of a wooden framework either supported on the
floor below or by side walls. The framework consists of a rigid arrangement of timber
members which may be plastered or covered with boarding etc from both the sides.
Such partitions are not fire-resistant and the timber forming the partition is likely to
decay or be eaten away by white ants. With the introduction of new building
materials, the use of timber partitions is getting gradually reduced these days.
The ease of installation of mechanical and electrical (M&E) services within the
boards will reduce the noise pollution that may be created with the hacking of brick
walls to embed the services, providing a cleaner and environmentally friendly site.
The drywall system can be easily installed and quickly relocated according to ones
needs. Homeowners can renovate and redesign the interior layouts within a short
time, there is no messy hacking of concrete or bricks and no debris to the
environment. The use of this system also facilitates dry construction that does not
require for messy plastering as its smooth and even surfaces are ready to receive
paint fi niches directly. Without the use of plastering, it would eliminate the possible
defects arising from low standard of workmanship. Such advantages have led
developers to use drywalls for various developments, including good class
residential projects.
For light and medium duty anchor for fi xtures such as mirrors, light fi tting or picture
frames on drywalls, simply use screwdriver to insert and tighten the screw until
secure. There is no need for hammer drills to make holes in concrete or brick and no
unsightly chunks of concrete or brick breaking out through imprecise workmanship.
The drywall system is also able to support heavy fi xture such as large wall
cupboards and heavy wall cabinets, but homeowners are advised to get contractors
to carry out the installation work with proper heavy duty anchors. Developers like
City Developments Limited, Capitaland Residential Limited, Far East Organization
and World Class Land have adopted high performance drywall system instead of
conventional brick walls in their recent projects, due to its quality and sustainability.
CONCLUSION
Malaysia need to use this IBS as it had a lot of positive impact to the construction
industry. When we use this system, it will uplift our level of construction industry
comparable with international construction industry level.
By using this system, we will speed up all the construction process since all the
building system are casting in the factory. When the system reached the site, it just
going through the assembling process.
The quality control of the site management will be increased. This is because, there
is no much works are being done on the site. The usage of tools and materials will
be reduced. It will facilitate all the workers to ensure the site are always in a good
condition.
When there is a good quality control, the number of accident occur in the site will be
decreased or maybe zero. With the good condition of site, it will easier the site safety
or site officer to do the regular inspection on the site condition and the machineries
used.