ibs chapter 1

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BFP 40603 INDUSTRIALISED BUILDING SYSTEMS (IBS)

CHAPTER 1 –

INTRODUCTION

TO IBS


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Content Summary

i. Overview of Malaysia’s construction industry

ii. Issues and the need of IBS

iii. IBS development in Malaysia

iv. IBS definition and related termsv. IBS benefits

vi. Challenges in IBS implementation

vii. From prefabrication, mechanisation to reproduction

viii. Case study - FASTBUILD – an attempt towards reproduction

ix. Conclusion

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Construction roboticsVision 2000 by French artist Villemard in 1910


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Malaysia Construction industry at a glance

Contribute 8% to GDP. 11.5% growth 2015.

Easily effected by economic condition

Government spending is reduce (except for infrastructure projects).

More private spending (70% in 2014)

TPPA professionals can open firm here and/or work borderless

64,000 contractors

More than 90% SME (less than 20 workers)

56% Bumiputra

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Increase in value in residential & non-residential building

5

15.5 13.1 12.3 16.120.9 25.0

30.5

20.3 24.3 27.1 25.227.5

29.334.318.2 17.2 15.7

18.3

28.232.3

32.7

4.4 5.4 5.64.7

4.1

4.3

5.0

0.0

20.0

40.0

60.0

80.0

100.0

120.0

2008 2009 2010 2011 2012 2013 2014

M Y R

( b i l l i o n )

Value of Projects Awarded by Sub-Sectors

Residential buildings Non-Residential buildings Civil Engineering Special Trade

Source: CIDB , printed March 2015


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The Klang Valley and Johor are the key areasof growth

19%

29%

28%

12%

Northern Pop: 6.42M

Double Railway Trackfrom Thai border toIpoh

Penang Outer RingRoad

Central Pop: 7.68M Pahang –

Selangor Water Transfer

Greater KL projects

LRT Extension

MRT project (RM 36bil)

LRT project

Tun Razak Exchange

Kwasa Development

Bandar Malaysia

Southern Pop: 5.47M

Petronas RAPID(Refinery andPetrochemical IntegratedDevelopment)

Southkey MixedDevelopment

Country Garden MixedDevelopment

Water Front MixedDevelopment

Medini Development

East Coast Pop: 4.42M

BioDiesel Plant at

Kuantan

Oil & Gas Industrial Park

at Pekan

Lanthanide processing

plant at Gebeng MCKIP (Malaysia-China

Kuantan Industrial Park)

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Source: CIDB , printed March 2015


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Malaysia construction industry

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Shortage of skilled labour Traditional practices & use of

conventional materials

Inconsistent quality Manual work


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Construction industry is not performing well atthis moment

2.5 years to deliver the project

High occupancy death per year (2014)

Construction – 69

Manufacturing – 58

Agriculture, fisheries and logging – 33

8% total workforce. 60% foreign workers. Total 4 millions

Local – 40% skilled. 60% unskilled

Foreign – 7% skilled. 93% unskilled

Productivity very low –RM 24,000 of output per year per employee

Malaysia – Retail – RM76,000, Transport – RM106,00, IT – RM 170,000

Construction – US – RM 57,000, China – RM 213,000, Aus. – RM 288,000

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Introduction of IBS in Malaysia

Introduced in 1999.

The use of pre-cast since 1960s –

Pekeliling Flat, PNKS house

IBS – precast, steel frame, blocks,

formwork, timber frame and

innovative solutions

Objective – Increase productivity.

Reducing manpower

1999 – IBS Strategic Plan

2003 – 2010 Roadmap

2011 – 2015 Roadmap

Catalogue IBS components

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IBS Thrust in the CIMP 2006-2015


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IBS policy milestone for Malaysia (1999-2010) (Source: CIDB, 2010)


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IBS Roadmap 2011-2015

The new IBS Roadmap 2011-2015 to

replace the current roadmap will be

published in late 2010.

The policy objective is to impose high level

intended outcomes of implementing IBS.

The new roadmap will be focusing on

private sector adoption of IBS. To remain

focus, it has been narrowed down to four

policy objectives; which are quality,

efficiency, competency and sustainability.

A sustainable IBS industry will contribute tothe competitiveness of the construction

industry.


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The pillars of the new roadmap are as follows :

1. Good quality designs, components and

buildings are the desired outcomes of IBS.

Aesthetics should be promoted through

innovations.2. To ensure that, by using IBS, completion time

of a building is speedier, more predictable and

well managed.

3. To have a ready pool of component IBS

professionals and workers throughout the

entire project lifecycle : from design,

manufacture, build and maintenance.

4. To create a financially sustainable IBS

industry that balances users affordability and

manufacturers viability.



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Four workstreams have been established as an

action plan to achieve the new roadmap pillars:Workstreams 1 : Institutional Strengthening

Workstreams 2 : Focusing on User

Workstreams 3 : Product Focus

Workstreams 4 : Industry Focus

Based on this workstreams, 37 action steps have

been recommended to be accomplished by 2015.

It is hoped that the roadmap will drive the way

forward for sustainable IBS adoptions; both in

public and private sector.

The goals for the Roadmap are encapsulatedbelow:

- To sustain the existing momentum of 70% IBS

content for public sector building projects through to

2015

- To increase the existing IBS content to 50% for private sector building projects by 2015



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IBS Definition

A construction technique in which components are manufactured in a

controlled environment (on or off site), transported, positioned and installed

into a structure with minimal additional site works (CIDB, 2003).

… an innovative process of building construction that incorporates: the

concept of mass-production of industrialised systems; produces products at

the factory or onsite within controlled environments; includes the logistical

and assembly aspects of it; and is coordinated with thorough planning and

integration (Kamar et al, 2003).

16Presentation name or chapter Date |


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IBS – other related terms

Modern method of construction

Prefabrication – a manufacturing process, generally taking place at a

specialised facility, in which various materials are joined to form a

component part of the final installation

Pre-assembly - process by which various materials, prefabricatedcomponents, and/or equipment are joined together at a remote location for

subsequent installation as a sub-unit. It is generally focused on a system

Off-site production (OSP)/off-site manufacturing (OSM)/off-site

construction (OSC) - part of the construction process which is carried out

away from the building, such as in a factory or sometimes in speciallycreated temporary production facilities close to the construction site or field

factories



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Classification of IBS MMC

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Classification of offsite system for different countries

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Countries Classification of offsite system Author

USA Offsite preassembly

Hybrid system

Panellized system

Modular building

Lu (2009)

UK Component manufacture and sub-

assembly Non-volumetric preassembly

Volumetric pre-assembly

Modular building

Goodier and Gibb (2004)

Australia Non-volumetric preassembly

Volumetric preassembly

Modular building

Blismas and Wakefield

(2008)

Malaysia Precast concrete systems

Formwork systems

Steel framing systems

Prefabricated timber framing systems

Blockwork systems

Innovative

(CIDB, 2003, 2010b)

.


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Level

number

Description Definition

Level 0 Basic Materials With no pre-installation assembly aspect

Level 1 Component sub-assembly Small sub-assemblies that are habitually

assembled prior to installation

Level 2 Non-volumetric pre-assembly Planar, skeletal or complex units made up

from several individual components – and

that are sometimes still assembled on-sitein ‘traditional’ construction

Level 3 Volumetric pre-assembly Pre-assembled units that enclose usable

space – can be ‘walked into’ – installed

within or onto other structures – usually fully

finished internally

Level 4 Modular building Pre-manufactured buildings – volumetric

units that enclose usable space but also

form the structure of the building itself –

usually fully finished

Level of industrialized production and definition (Source: Gibb, 1999).


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BENEFITS OF IBS

Low site workers requirement due tosimplified construction methods

Quality controlled and highly

aesthetic end products through the

process of controlled pre-fabricationand simplified installations

Reduction of construction materials

at sites through the use of pre-

fabricated components

Reduction / elimination of

conventional timber formwork,replaced by pre-fabricated

components and alternative

moulds with multiple usage

capability

Cleaner sites due to lesser

construction waste

Safer construction sites due to thereduction of site workers, material

and construction waste

The repetitive use of system formwork

made up steel, aluminum, etc and

scaffolding provides considerable costsavings.

Construction operation is not affected by

adverse weather condition because pre-

fabricated component is done in a factory

controlled environment.

Pre-fabrication takes place at

centralized factory, thus reducing labour

requirement at site.


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BENEFITS OF IBS

1) Save construction time



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DISADVANTAGES

The size being very gigantic:

Difficulty in sending the components

but also it needs specific and large

type of formwork.

Needs large area for building thefactory, place to store the products and

movement of the lorry and so on.

The design of joints is one difficult

matter and need great expertise:

Joint is important to give the

suitable strength

Problem at home where there’s

leakage between the joints


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DISADVANTAGES

The handling of the components needs

the involvement of heavy vehicles

such as trailers which needs a huge

amount of expenses:

It is expensive if compared to theconventional system

Only suitable if done in a large scale,

meaning small-scale projects are not

economical

Hard to do the renovation works:

If the precast panel is used and

renovation works needs to be done,

then it’s a big possibility that the whole

wall needs to be demolished.


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We have good policy and incentives in placeon IBS

Introduced in 2005 – privateresidential project – IBS score

more than 50 contractor is

exempted to pay CIDB levy

(0.0025% construction value)

In 2008, all government projectvalue RM 10 million need to have

IBS score 70

In 2016, private sector – IBS Score

55 (project value more than RM 50

millions)

RM 500 millions soft loans to

developers and contractors in the

category of G5 and below (Budget

2016)

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However, only 24% targeted public sector useIBS. Private – 15%

IBS is not implemented asholistic – only product

replacement exercise

Thinking and coordination still

conventional

Construction still – 2 years

High cost – if apple to apple

Precast beam and column – wall

using bricks – hardly improve

productivity and reduce

construction time

Workers issues

Coordination issues – M&E

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Pivotal questions & Hypothesis

PQ

How to develop IBS that are holistic that give overall benefit to the

implementers rather than a product replacement exercise?

Hypothesis

IBS should look beyond product by understanding the level of industrialisation

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Degree of industrialisationRoger-Bruno Richard,1998

Prefabrication

Mechanisation

Automation

Robotics Reproduction

High

Low

http://localhost/var/www/apps/conversion/tmp/VIDEO%20IBS%20CENTER/gantenbein.wmvhttp://localhost/var/www/apps/conversion/tmp/VIDEO%20IBS%20CENTER/gantenbein.wmv


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Prefabrication

Prefabrication is a manufacturing

process that generally takes place

at a specialized facility (factory) or

onsite

Small scale production. Use largenumber of semi-skilled labour

along production line and onsite

Small number of machines and

equipment

Non-complex machines andequipment


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Degree of IndustrialisationRoger-Bruno Richard, 1998

Prefabrication

Mechanisation

Automation


High

Low



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Mechanisation

Extensive usage of mechanicaland electrical equipment and

machineries in aiding

prefabrication and construction

activities

Machine is still controlled by labour

Use of complex machines and

equipment

Machines substantially reduce the

need of manpower as compared toprefabrication


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® J&P Building Systems, UK. Manufactured by Evans Concrete, UK


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Prefabrication

Mechanisation

Automation


High

Low



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Automation

Automation is defined as a self-

regulating process performed by

using programmable machines to

carry out series of tasks.

Automation is also a situation

when the tooling (machine)

completely takes over the tasks

performed by the laborer.


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Mass-customization


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Prefabrication

Mechanisation

Automation


High

Low



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Robotics

Ability of the same tooling whichhas the multi-axis flexibility (robotarm) to perform diversified tasksby itself

Consist of using high technologymachine with total control ofmachines using artificial intelligentcapability

Eliminate the need of manpower

Happen in other industry usingof drones


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Using drone to construct building


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Construction Robotics


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Robotic Construction of High Rise Buildings


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Prefabrication

Mechanisation

Automation


High

Low



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Reproduction

Innovative processes are trulycapable of simplifying the production

process or complex goods by

introducing a different technology

3D printing technology

Reengineering of processes –printing of component or the whole

house

Materials – cement fiber and other

materials


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3- D Printing Technology

The “ink” used for 3D printed houses is based on high


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The ink” used for 3D printed houses is based on high-grade cement and glass fibre.

The objectives of IBS achieve via


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The objectives of IBS achieve viaindustrialisation

Prefabrication – Increase the number ofcomponents that are fabricate offsite –IBS

Mechanisation – Increase the use ofmechanical and electrical equipment toaid process (site & prefab yard)

Automation – we can increaseautonomy of a machines thus reducingmanpower

Robotics – we can handover the task tomechanical arm thus eliminating the

need of manpower Reproduction – reengineering of

processes and look into material toeliminate manpower

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Basic and

fundamental

objectives of IBS

Productivity and

manpower

reduction


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A self-compacting and self leveling concrete that


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A self-compacting and self leveling concrete thatprovides solutions for design & placement


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Agilia Normal Concrete

Spread/Slump Spread 650mm to 750mm Slump 50mm to 100mm

Initial setting 4-5hr 4-5hr

Compressive

strength at 28days

35MPa – 50MPa 25MPa – 50MPa

Pumping discharge

rate

1m3/min 0.6m3/min

Achievable

compressivestrength at 12hr

10MPa 10MPa

Levelling Self levelling properties Requires troveling

Compaction No vibration needed Requires vibration or

external energyWorkability High Low

Retention period 2hr 2hr

Wall surface finish Reduced air trapped Requires vibration to

reduce air trapped


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Comparing two building systems

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CONVENTIONAL FASTBUILD

Beam and column system using G30

concrete. Non-load bearing cement-

sand bricks as structural envelope and

partition walls. Flat roof (concrete)

1. Construction of foundation(Reinforcement bars + concrete)

2. Casting of floor slab

(Reinforcement bars + concrete)

3. In-situ/precast column construction

(Reinforcement bars + concrete)4. In-situ/precast beam construction

(Reinforcement bars + concrete)

5. Brick laying & plastering

Monolithic system (in-situ single

cast) . All using reinforced concrete

(envelope structure including

partition walls). Flat roof (concrete)

1. Installation of vertical rebar &wall formwork

2. Installation of horizontal rebar &

deck formwork

3. Formwork alignment and Agilia

concreting

4. Removal of formwork

VS


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4 days to build a house structure

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Day 1 – Installation of vertical rebar & wall

formwork

Day 2 – Installation of horizontal rebar & deck

formwork

Day 3 - M & E, formwork alignment and Agilia

concreting

Day 4 - Removal of formwork

- Wall at 12 hours (concrete strength 2 MPa)

- Deck at 24 hours (concrete strength 20 MPa)

Watch video

1

2

3

4

http://localhost/var/www/apps/conversion/tmp/scratch_6/Laf-CDL-MFE-House-Timelapse-(3%20day%20cycle+1%20day%20striking)-v2.mp4http://localhost/var/www/apps/conversion/tmp/scratch_6/Laf-CDL-MFE-House-Timelapse-(3%20day%20cycle+1%20day%20striking)-v2.mp4


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We built 2 houses to compare the speed & cost

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FastBuildConventional formwork

(timber)

The results

36% savings in cost

84% savings in time

The save 36% of total construction cost


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The save 36% of total construction cost(structure only)

FastBuild Conventional System Percentage of saving

(based on 100repetition)• Based on project at

CDL platform

• Comparison on

structure only which

involved our products

• Checked and verifiedby chartered Quantity

Surveyor

RM 35,209.00 RM 55,746.00 36 %

1. Formwork

2. Reinforcement bars3. Concrete

1. Formwork (beam &

column)2. Reinforcement bars

3. Concrete

4. Bricklaying

5. Plastering

Additional works in

bricklaying andplastering. Not material

to material comparison

– include labour

Our system save 84% of total construction


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Our system save 84% of total constructionduration (structure) – reducing site risk

FASTBUILD Conventional System Percentage of saving

(Based on 100

repetition)

4 days (until the point of

skim coat)

25 working days (until

the point of skim coat)

84 %

Involved installation of

reinforcement bars,

formwork and

concreting only

Involved all wet trades –

brick laying, plastering

and hacking to install

electrical conduit


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Eliminate plastering and bricklaying

Construction completed

much earlier at Day 4

Construction completed at

Day 25

Bricklaying stage& wall hacking to

install electrical

conduit

Plastering stage

Electrical conduit was installedduring formwork formation

Our system save 82% of total workers on site


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Our system save 82% of total workers on site(man-hours) – reducing workers onsite

Monolithic Building

System

Conventional System Percentage of saving

(Based on 100

repetition)

45 x 8hrs.

= 360 man-hours

244 x 8hrs.

= 1,952 man-hours

82 %

Semi-skilled for

formwork installation

& concreting in short

construction period

Brick layers,

carpenters and

plasterers in long

construction period

Saving – mitigate

issue on skilled

workforces and

reducing dependency

on foreign workers

Manpower requirement for Convectional


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p qSystem

59

NO ACTIVITY

Settingout,installationofrebar&

columnsformwork

Columnsconcretingwork

Strikingcolumnsformwork

FabricationreinforcementforRoof

Slab,Roofslabformworkpreparation

Roofslabformworkpreparation,



Concretingworkforshortcolumns,

Strikingsplayformwork

Adjustingpropsystem

andtightenthe

Brickwallsettingout,lintol

Stiffenerconstructionforbrickwall,

Materialandworkareapreparation

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Bricklayingforwall

Electricalsettingoutandwallcutting

Cuttingbrickwallforconduitfixing

Conduitfixingandpatchbackthearea

Conduitfixing,switchbaseinstallation

Plasteringworks

Plasteringworks

Plasteringworks

Plasteringworks

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16 16 16 14 14 14 14 14 14 14 14 16 17 18 19 20 21 22 23 24 25

1 P roject Supervisor i- Civil

ii- Structural 1 1 1 1 1 1 1 1 1

iii- Architectural 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

v- Safety supervisor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

2 Carpenter 4 4 4 4 4 4

3 Bar Bender 2 2 2 2 2 2 2

4 Concreter 4 4

5 Electrical 2 2 2

6 General Worker 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

7 Plasterer 4 4 4 4

8 Brick Layer 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4 4

9 9 9 9 9 9 9 7 4 3 3 3 3 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 7 3 5 5 5 7 7 7 7Total

Days

Calculation of man-hour

244 x 8 = 1,952 man-hour

Manpower requirement for Monolithic Building


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p q gSystem

Calculation of man-hour

45 x 8 = 360 man-hour

4 days cycleNO ACTIVITY

Settingout,installationof

rebar&Internalwallform

work

Electricalconduit,External

wall&Roofformwork.

Roofslabreinforcement,

dropframepanel,conduit,

pre-concretinginspection&

concreting

Strikingformwork,formwo

rk

panelcleaning

1 2 3 4

1 Project Supervisor

i- Civil

ii- Structural 1 1 1 1

iii- Architectural

v- Safety supervisor 1 1 1 1

2 MFE/Carpenter 8 8

3Bar Bender 3 3

4 Concreter 3

5 Electrical 2 2

6 General Worker 2 2 2 2

9 17 7 12

Days

Total


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In summary…

The fundamental of IBS increase productivity and reduction of workers

Thus, IBS need to be redefine beyond product

It involve ‘industrialisation effort’ – process, people and materials

Need to increase the level of industrialisation – looking at the larger

perspective of prefabrication, mechanisation, automation and reproduction

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ibs chapter 1

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