GREETINGS

I would like to thank to my beloved lecturer , En Shahrin bin Shafie, En Abdul Rahim bin Sarjan and Puan

Hadizah binti Mohamad Kassim. for their valuable supervision based on their

commitment at thesame time as they have given me full freedom in the research work. Duringthe research process I have benefited

from their experience and creativesuggestions.

TABLE OF CONTENTS

GREETINGS INTRODUCTION TO INDUSTRIALISED

BUILDING SYSTEM TYPES OF INDUSTRIALISED BUILDING

SYSTEM ADVANTAGES AND DISADVANTAGES

(IBS) MMC PREFABRICATED BUILDING CONCLUSION

INTRODUCTION

Since 2003, the government of Malaysia together with its agency, the Construction IndustryDevelopment Board has been aggressively pushing the construction industry to use of theIndustrialised Building System (IBS) method of construction. It is part of an integrated effort tofurther enhance the capacity, capability, efficiency and competitiveness of the industry and alsoto reduce the industry’s reliance on foreign workers. It is also an effort to promote cleaner, safer,simpler and efficient method of construction. Many considered it as novel effort but somesections of the industry are very concern of its impact on hundreds of small and medium sizedtraditional contractors, trade sub-contractors and material and component suppliers. Theiranxiety is well placed. As most of us already know, IBS is a construction system founded on theconception that “construction is also manufacturing” where by most of construction componentsand parts are manufactured (fabricated) in the factory and transported to site for assembly. Suchmethod of construction will most likely eliminate the role and function of the many of small andmedium sized general contractors as well as the traditional trade sub-contractors. The use oflarge pre-finished factory made components or parts will most likely diminish the need for smalltraditional trade sub-contractors whose business are in the sub-contract works such asconcreting, bar bending, bricklaying, plastering, tiling, carpentering, painting etc.

WHAT IS INDUSTRIALISED BUILDING CONSTRUCTION?

Industrialised Building System (IBS) is a term used in Malaysia for a technique of construction where by components are manufactured in a controlled environment, either at site or off site, placed and assembled into construction works.[1] Worldwide, IBS is also known as 

Pre-fabricated /Pre-fab Construction, Modern Method of Construction (MMC)  and Off-site Construction.

CIDB Malaysia, through IBS Centre is promoting the usage of IBS to increase productivity and quality at construction sites [2] through various promotion programmes, training and incentives. The content of IBS (IBS Score) is determined based on the Construction Industry Standard

all building components such as :

wall, 

floor slab, beam,

column and

staircase

are mass produced either in factory or at site under strict quality control and minimal on site activities (Rollet, 1986; Trikha, 1999).

 

5 main IBS groups.

Pre-cast concrete frames, panels, columns etc

Formwork systems - tunnel forms, permanent steel formworks

Steel frame systems - portal frame, roof trusses

Prefabricated timber frames - i.e. for roof trusses

Block work systems - lightweight concrete blocks and so on...

Types of IBS

1. Precast concrete - Proven Prestressed Concrete Half Slab

(considered as High End Product of precast concrete) which simplify

and expedite the construction of floor slab (is the critical activity in

the construction process), very adaptable to all other systems

(including conventional) which makes it a very popular IBS

component. It is highly demanded for all types of building

construction. 

2. Formwork - Proven Plastech Formwork (using material of high

strength plastic as formwork) is a green building material (unlike

metal formwork). It is very light and require less capacity crane for

handling. The insitu concrete does not stick to the surface of the

formwork which makes the end product of the surface which makes

the end product of the concrete wall, very smooth and ensure good

quality for the sebsequent finishes work. 

5. Blockwork - PGC produce Proven Interlocking Engineering Block

and Brick. The Proven Interlocking Engineering Block is designed as

load bearing wall system. It can easily be installed (like lego

system) and transferred into Do It Yourself Concept (DIY). The

proven Interlocking Bricks can be utilised as a load bearing wall

system, as well as infill. Both products are installer friendly, fast and

easily laid vertically, resulting in quality wall finishes.

6. Hybrid/Innovative - PGC had implemented successfully by

combining all the above IBS Systems (1+2+5) formultilevel

buildings higher than five storeys. We name these combination as

Proven IBS Hybrid System. 

ADVANTAGES DISADVANTAGESSpeed

2 times faster than conventional

method

Conventional method of making the

floor is about 14 days. With our Pre-

Stressed Half Slabs, it will  take

only 2 days.

Reduces workers

Reduces the need for skilled

workers, carpenters and bar-

benders

Systematic way

Wall: M&E piping & conduits can be

placed with no hacking required

Floor: Slabs can just be arranged

like planks speedily

Both products are made by moulds,

which creates size consistency

No formwork required

With our wall, no formwork is

required as it will all be

incorporated into the blocks.

Environmental-friendly

Less formworks and less wastages

Air gap feature helps heat and

sound insulation

Smooth surface finishes

Wall: Smooth and straight due to

the tongue and groove feature

Floor: smooth surface which will

lead to savings in finishes

Savings

high initial capital costs for the contractors –

lack of aesthetics value - buildings tend to be very boxy and square-y, which may not look as impressive

bad workmanship while using pre-fabricated panels. 

result in problems in the joints - resulting in water leakages.

pre-cast elements is that these components are considered to be inflexible,

heavy,

not insulated

not attractive

INCREASED TRANSPORTATION LOGISTICS REQUIREMENTS

LIMITED NUMBER OF PROVIDERS EARLY COMMITMENT

TO ENGINEERING ANDDESIGN WORK

TIME : 50% faster than conventional

STEEL: save 50% usage as less steel needed for the wall and slabs

FOUNDATION: our system is lighter than conventional, so can save on foundation

FINISHES: smooth surfaces means less work on finishes (plastering and skimcoat)

WORKERS: less dependency on plumbing, M&E, carpenters, bar-benders and skilled general workers

 

working environment in a factory is easier to control. Simple erection with developed jointing methods on site to obtainhigher productivity at the site.

MODERN METHOD CONSTRUCTION (MMC)

Modular construction involves the manufacture and fitout of steel framed building modules within a factory controlled environment, whilst ground works and foundations are prepared on site. The modular units are then delivered to site and craned into position to form the building.

Precast Flat Panel SystemFloor and wall units are produced off-site in a factory and erected on-site to form robust structures, Panels can include :

services,

windows,

doors

finishes.

3D Volumetric Construction

 involves the production of three-dimensional units in controlled factory conditions

prior to transportation to site.

Modules can be brought to site in a variety of forms, ranging from a basic structure

to one with all internal and external finishes and services installed,

 inherent benefits of concrete, :such as

thermal mass , 

sound  

 fire resistance,

as well as offering factory quality and accuracy, together with speed of

erection on-site.

Tunnel FormTunnel form is a formwork system that allows the contractor to build monolithic walls and slabs in one operation on a daily cycle. It combines the speed, quality and accuracy of factory/offsite produced ready-mix concrete and formwork with the flexibility and economy of cast in-situ construction.

Flat SlabsFlat slabs are built quickly due to modern formwork being simplified and minimised. Rapid turnaround is achieved using a combination of early striking and flying formwork systems.

Thin Joint MasonryThin Joint Masonry allows the depth of the mortar to be reduced from 10mm to just 3mm or less, resulting in faster laying and improved productivity, particularly on long runs of walling. Construction speed can be further increased by some 13.5 per cent using large-format concrete blocks

Insulating Concrete FormworkInsulating Concrete Formwork (ICF) systems consist of twin-walled, expanded polystyrene panels or blocks that are quickly built up to create formwork for the walls of a building. 

Precast Foundations

Precast concrete systems can be used to rapidly construct foundations. The elements are usually to a bespoke design and cast in a factory environment, giving assured quality for the finished product. The foundations are often supported by concrete piles and connected together.

improve productivity

 

Superstructure Components

– _Volumetric or modular construction.Factory produced three-dimensional units that are thentransported to site and bolted together. The frames willnormally be steel, timber or concrete and can be suppliedwith all external and internal finishes (including servicessuch as electrics and plumbing), or solely the basicstructure.

– _Pods.Factory produced three-dimensional elements that areincorporated into the superstructure of a building. Theseare ready made rooms which can be pieced together tomake complete premises when set within a light steelframework.

– _Panellized.actory produced flat panel units transported to site for

assembly. Typically these would form the exterior walls ofthe building – they can be load-bearing (ie. providingstructural support) or non-load-bearing. They can bemade of timber, light gauge steel, structurally insulatedpanels (SIPs), concrete or non-structural in-fill walling usedto create the whole building.

– _Hybrid.These structures combine both volumetric and panellisedapproaches within the same building and are also knownas semi-volumetric.

– _Timber framed.Timber framed buildings have been around for hundredsof years, however, the concept is now being used tocreate some much larger and more innovative structures

– _On-site manufacture.

Site based assembly methods include the use of traditionalcomponents but in innovative designs including theestablishment of manufacturing facilities at construction

SITES.

LIGHTWEIGHT CLADDING SYSTEMS

Brick slipsIndividual brick slices that are fixed vertically by adhesive.Normally brick slips will be glued to plastic wall facingsheet though they are also available in larger panels thatare hung onto the superstructure.Rain screenThese are weatherproof external coverings that are easilyfixed to factory produced framework attached to thebuilding and can be made from metals, ceramics, granite,terracotta, vitreous enamel, laminates and timber.Insulation material may be present behind the cladding.Render systemsRender is an external covering applied to the outside of abuilding, usually directly on to bricks, blockwork, boardsor insulation. It is normally made from limestone, cementand polymers and can be produced in a wide variety ofcolours and finishes. The actual render is non-combustible,but the covered material to which it is applied can oftenbe combustible (eg. foam plastic insulation).Timber claddingAlthough a traditional building material the use of timbercladding has become increasingly common in recent yearsalongside the desire for increased use of sustainablebuilding materials. For new commercial buildings it iscommonly used in combination with other claddingsystems, although it can form the majority of the externalarea of the building.External Insulated Finish Systems (EIFS)

These systems involve attaching insulation material directlyto an external wall that is then covered with a render orother type of finish such as tiles, metal or brick. There areventilated and non-ventilated systems, the former havingan air gap between the insulation and the exteriorcovering. The insulation used is very often a foam plasticmaterial (eg. expanded polystyrene) which is highlycombustible when exposed to fire.Lightweight cladding systemsAs many of these method and forms of construction arenew there is a level of uncertainty how they will performover time and the impact that might arise on thefrequency and size of loss. Issues which need to beconsidered in relation to MMC buildings include:• The use of lightweight and combustible materialsmay allow a greater degree of fire spread leadingto increased claims costs. Similarly the use ofcombustible materials externally may increasepotential for damage from external fires whetherdeliberate (arson) or accidental.• Where component parts are fixed together (notablymodules and

PREFABRICATION

conventional method of building a house is to transport bricks, timber, cement, sand,steel and construction aggregate, etc. to the site, and to construct the house on site from these materials.

In prefabricated construction, only the foundations are constructed in this way, while sections of walls, floors and roof are prefabricated (assembled) in a factory (possibly with window and door frames included), transported to the site, lifted into place by a crane and bolted together.

Prefabrication is used in the manufacture of ships, aircraft and all kinds of vehicles and machines where sections previously assembled at the final point of manufacture are assembled elsewhere instead, before being delivered for final assembly.

the structure is composed of repeating units or forms, or where multiple copies of the same basic structure are being constructed. Prefabrication avoids the need to transport so many skilled workers to the construction site, and other restricting conditions such as a lack of power, lack of water, exposure to harsh weather or a hazardous environment are avoided. Against these advantages must be weighed the cost of transporting prefabricated sections and lifting them into position as they will usually be larger, more fragile and more difficult to handle than the materials and components of which they are made.

EXAMPLE OF THE BUILDING

Tesco  modular store in Zub ř í , Czech  

McDonalds  

REFERENCES

[1]- (CIDB 2005-a), Construction Industry Development Board (CIDB) Malaysia, “Precast Concrete Construction”, IBS Digest January – March 2005 Issue, 2005, pp 11-14.

[2]- (CIDB 2007-a), Construction Industry Development Board (CIDB) Malaysia, “The First Industrialized Building System (IBS) Timber House (TH) in Malaysia”, Contributor: Ar. Zulkifli Hj Ismail (UIAM), IBS Digest 01-2007 Issue, 2007, pp 8.

[3]- (CIDB 2005-b), Construction Industry Development Board (CIDB) Malaysia, “IBS a Short History”, IBS Digest July-September 2005 Issue, 2005, pp 11, 12.

Wikipedia Eric;s yong blog Book Charles, T. M and Louis, F. S. (1995). Making A Difference: Measuring the

Impact of Information on Development. Canada: The International Development Research Centre. Cox, A., and Townsend, M. (1998). Strategic procurement in construction.

Thomas Telford, London. Magazine CIDB. (2008). Construction and IBS Industry – At a Glance (2008). IBS

Digest, 01, 1 Industrialised Building System – A Brief Background. IBS Modular Buletin

(February, 2008)

CONCLUSION

As highlighted earlier in this paper, in 2003, the government has embarked on the program topromote the greater use of IBS in the country by announcing that all public projects must contain70% of IBS components. Although it is a welcoming initiative, several quarters, such as micro,small and medium companies and suppliers are worry that the move may force them to closedown their business or they have to move their businesses somewhere else. Their concerns haveground because Figure 1, 2, 3 and 4 suggested that the use of IBS will likely eliminate many ofthe traditional processes. Consequently, it will eliminate the need many of the traditional tradecontractors and suppliers. By comparing Figure 1 and 2, it can be seen that the traditional processof bricklaying, bar-bending, plastering will be gone. By comparing Figure 3 and 4, the traditionalwork of concreter, bar-bender and carpenter will also not be needed when IBS is used.

As a conclusion, it can be suggested that considerable numbers of construction related businessin the form of trade contractors may not be able to continue their business when the industry ismoving towards greater use of IBS. Therefore, it is very apt to carry out a more detailed study onthe implication of greater use of IBS on construction business community.