i

THE EFECTIVENESS OF COST AND TIME ON VARIOUS TYPE OF IBS

SYSTEM

GOH TUAN LEONG

UNIVERSITI TEKNOLOGI MALAYSIA

ii

UNIVERSITY TEKNOLOGI MALAYSIA

DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT

Author‟s Full Name: GOH TUAN LEONG

Date of birth : 15TH

FEBUARY 1990

Title EFECTIVENESS OF COST AND TIME ON VARIOUS TYPE OF IBS

SYSTEMS

Academic Session: 2013/2014

I declare that this thesis is classified as:

CONFIDENTIAL (Contains confidential information under the Official Secret

Act 1972)*

RESTRICTED (Contains restricted information as specified by the

Organisation where research was done)*

√ OPEN ACCESS I agree that my thesis to be published as online open access

(full text)

I acknowledged that Universiti Teknologi Malaysia reserves the right as follows:

1. The thesis is the property of Universiti Teknologi Malaysia.

2. The library of Universiti Teknologi Malaysia has the right to make copies

for the purpose of research only.

3. The library has the right to make copies of the thesis for academic exchange.

Certified by:

SIGNATURE SIGNATURE OF SUPERVISOR

900215-03-5213 ASSOCIATE PROFESSOR SR DR ZAKARIA MOHD YUSOF

(NEW IC NO. / PASSPORT NO.) NAME OF SUPERVISOR

Date: Date:

NOTES :*If the thesis is CONFIDENTIAL or RESTRICTED, please attach with the letter from the

organization with period and reasons for confidentiality or restriction.

i

SUPERVISOR’S DECLARATION

“I/We* hereby declare that I/we* have read this thesis and in my/our*

opinion this thesis is sufficient in terms of scope and quality for the

award of the degree of Bachelor in Quantity Surveying (Honours).”

Signature : .........................................................

Name of Supervisor I :ASSC PROF SR DR ZAKARIA

MOHD YUSOF

Date : .........................................................

Signature : .........................................................

Name of Supervisor II : DR NAFISAH BT RAHIMAN

Date : .........................................................

ii

EFFECTIVENESS OF COST AND TIME ON VARIOUS TYPES OF IBS

SYSTEMS

GOH TUAN LEONG

A dissertation submitted in partial fullfillment of the

requirements for the awards of the degree of

Bachelor of Quantity Surveying

Faculty of Build Environment

Universiti Teknologi Malaysia

DECEMBER 2013

iii

DECLARATION

I declare that this thesis entitled “ Effectiveness of Cost and Time For Various Types

of IBS Systems ” is the result of my own research except as cited in the references.

The thesis has not been accepted for any degree and is not concurrently submitted in

candidature of any other degree.

Signature : ....................................................

Name : ....................................................

Date : ....................................................

GOH TUAN LEONG

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DEDICATION

To my beloved family and friends.

Thanks for your supports and encouragements

Supervisor and Panels,

Thanks for your guidance and criticism

Thanks for Everything Granted

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ACKNOWLEDGEMENT

Firstly, I would like to thank my Supervisor, AP SR DR ZAKARIA MOHD

YUSOF for his willingness to share his knowledge and spend out his precious time

to give me guidance, advices and support for me to accomplish this research. I

would also like to thank my lecturers and also to my second reader for giving me

guidance in my research.

Secondly, I would like to thank to my family and friends for their supports

and dedication in helping me to accomplish the research. Besides that, sincere

gratitude is exclusively expressed to Perpustakaan Sultanah Zanariah (PSZ),

Universiti Teknologi Malaysia which had subscribed the international prominent

journals and reading materials to enable me to capture the important information for

the research.

Last but not least, thankful are extended to all my case study respondents for

their cooperation and useful information given. I would like to thank to all my

friends, buddies, course mates who helped me in this research. Thank to you all.

vi

ABSTRACT

Not many among us all except those who are in the midst of progressive

development in the heart of the capital really understood the concepts and

technologies lay behind the Industrialized Building System or simply known as IBS

amongst the construction and build communities. Unrealized, the Government of

Malaysia has put a lot of effort to start the implementation of IBS in their

construction contract and roadmap for IBS toward 2015. Nevertheless, the industry

stakeholders are indifferent of this idea and thus resist toward this change which

probably due to ignorance, perhaps lack of idea and awareness or lack of effort in

understanding the concept and cost in technology transfer due to the initial high cost

in implementation however these technologies enable to reuse for reoccurring

processes. Objectives, this research is to identify the various types of IBS systems

used in our construction industry and evaluate the cost and time of various type of

IBS system, which the result of analysis showed the Precast Framing, Panel and Box

Systems is the most effective IBS system. Case study method has been used as this

research methodology for the research study and descriptive statistics had been used

for analysed the research. Finally the finding result of research shows there are 3

types of IBS systems that are frequently practice in our construction industry. Those

three types of IBS systems are Precast Concrete Framing, Panel and Box Systems,

Steel Formwork Systems and Block Work Systems. The finding of result also shows

the Precast Concrete Framing, Panel and Box Systems is the cheapest and fastest of

IBS and Steel Formwork Systems is the expensive and slowest of IBS.

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ABSTRAK

Tidak ramai di kalangan kita semua kecuali mereka yang berada di tengah-

tengah pembangunan progresif di tengah-tengah ibu negara benar-benar memahami

konsep dan teknologi di sebalik Sistem Bangunan Perindustrian atau hanya dikenali

sebagai IBS di kalangan pembinaan dan membina komuniti. Tanpa disedari, kerajaan

Malaysia telah meletakkan banyak usaha untuk memulakan pelaksanaan IBS dalam

kontrak pembinaan dan pelan tindakan untuk IBS ke arah 2015. Walau

bagaimanapun, pemegang kepentingan industri tidak mempedulikan idea ini dan

dengan itu menahan ke arah perubahan ini yang mungkin disebabkan oleh kejahilan ,

mungkin kekurangan idea dan kesedaran atau kekurangan usaha dalam memahami

konsep dan kos dalam pemindahan teknologi kerana kos awalan yang tinggi dalam

pelaksanaan bagaimanapun teknologi ini membolehkan untuk menggunakan semula

untuk proses sering muncul . Objektif kajian ini adalah untuk mengenalpasti pelbagai

jenis sistem IBS yang digunakan dalam industri pembinaan dan menilai kos dan

masa pelbagai untuk pelbagai jenis sistem IBS, di mana hasil analisis menunjukkan

Precast Framing, Panel dan Box Systems adalah sistem IBS yang paling berkesan

dari segi kos dan masa. Kaedah kajian kes telah digunakan sebagai kaedah

penyelidikan ini untuk kajian penyelidikan dan statistik diskriptif telah digunakan

untuk dianalisis penyelidikan. Akhirnya hasil dapatan kajian menunjukkan terdapat 3

jenis sistem IBS yang sering amalan dalam industri pembinaan . Ketiga-tiga jenis

sistem IBS adalah Precast Framing, Panel dan Box Systems, Steel Formwork

Systems dan Block Work Systems. Hasil daripada kajian juga menunjukkan Precast

Concrete Framing , Panel dan Peti Systems adalah yang paling murah dan paling

cepat IBS dan Acuan Keluli Sistem adalah mahal dan paling perlahan dalam IBS.

viii

TABLE OF CONTENT

CHAPTER TITLE PAGE

DECLARATION iii

DEDICATION iv

ACKNOWLEDGEMENT v

ABSTRACT vi

ABSTRAK vii

TABLE OF CONTENT viii

LIST OF TABLE xiii

LIST OF FIGURE xv

LIST OF ABBREVIATION xvii

LIST OF APPENDIX xviii

CHAPTER 1 INTRODUCTION 1

1.1 Background of Study 1

1.2 Issues 3

1.3 Problems Statement 4

1.4 Research Questions 5

1.5 Objective of Study 5

1.6 Significant of Study 5

1.7 Scope of Study 6

1.8 Methodology Research 6

1.9 Organisation Research 8

CHAPTER 2 EFFECTIVENESS OF COST AND TIME FOR THE VARIOUS

TYPE OF IBS SYSTEMS 11

2.1 Introduction 11

2.2 Definition of IBS 12

2.3 Precast Concrete 14

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2.4 Pre-Fabrication Technology 15

2.4.1Classification of Pre-Fabrication System 16

2.4.2 Materials 17

2.4.2.1 Wood 17

2.4.2.2 Steel 18

2.4.2.3. Aluminum 18

2.4.2.4. Concrete 19

2.4.2.5. Plastics 19

2.4.2.6 Structural System 20

2.4.2.7 Frame Assembly 20

2.4.2.8 Frame Panels 20

2.4.2.9 Stressed Skin Panels 21

2.4.2.10 Solid Panels 21

2.4.2.11 Poured at Site 22

2.5 Classification of IBS Systems 22

2.5.1 Classification According to Structural System 23

2.5.1.1 Linear System or Frames (beam and column) 23

2.5.1.2 Panel System 24

2.5.1.3 Rectangular or Boxes system or Three Dimensional System

24

2.5.2 Classification According to Material 24

2.5.2.1 Timber 25

2.5.2.2 Bricks and Block Works 25

2.5.2.3 Steel 25

2.5.2.4 Reinforced concrete 25

2.5.3 Classification According to Relative Weight of Components 26

2.6 Characteristics of IBS Systems 27

2.6.1 Essential Characteristics of IBS Systems 29

2.6.1.1 Closed System 29

2.6.2 2Open System 30

2.6.3 Standardisation and Tolerances 31

2.6.4 Specialisation 31

2.6.5 Good Organisation 31

2.6.6 Integration 32

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2.6.7 Equipment at Site 32

2.7 Type of IBS 32

2.8 Benefits of IBS 36

2.9 IBS Implementation 38

2.10 Promotion of IBS in Malaysia 39

2.11 Roadmap Towards Making IBS A Success In Malaysia 41

2.12 Construction Cost 46

2.13 Cost Control 48

2.13.1 Importance of Cost Control 48

2.14 Time and Duration of Project 49

2.15 Time for Completion 49

2.16 Conclusion 50

CHAPTER 3 RESEARCH METHODOLOGY 52

3.1 Introduction 52

3.2 Research Process And Procedure 52

3.2.1 Identify The Problems and Research Objective 53

3.2.2 Literature Review 53

3.2.3 Data Collection 53

3.2.4 Data Analysis 54

3.2.5 Method of Analysis 54

3.2.6 Conclusion and Recommendation 54

3.3 Research Sampling 55

3.4 Research Instrument 56

3.4.1 Section 1: Project Background 56

3.4.2 Section 2: Types of IBS System Apply by Project 57

3.4.3 Section 3: Cost and Time Information of IBS Project 57

3.5 Data Collection 58

3.6 Data Analysis 58

CHAPTER 4 DATA ANALYSIS 60

4.1 Introduction 60

4.2 Projects Background 61

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4.3 Types of IBS Used By The Projects 63

4.3.1 Component of Building Constructed By IBS 65

4.4 Analysis of Cost 66

4.4.1 Total Cost of Projects and Cost / Gross Floor Area 66

4.4.2 Breakdown Cost and Cost /M2 of IBS Project Elements 68

4.4.2.1 Breakdown Cost of Element and Cost / M2 for Steel

Formwork Systems 68

4.4.2.2 Breakdown Cost and Cost / m2 of Element for

Block Work Systems 71

4.4.2.3 Breakdown Cost and Cost / m2 of Element for

Precast Concrete Framing, Panel and Box System. 73

4.4.3 Comparison of Cost / m2 for IBS‟s Projects 76

4.4.3.1 Comparison of Cost / m2 For Steel Formwork 76

4.4.3.2 Comparison of Cost / m2 For Block Work System 78

4.4.3.3 Comparison of Cost / m2 For Precast Concrete

Framing, Panel and Box System 80

4.4.4 Overall Comparison Average Cost / m2 for IBS Project 81

4.5 Analysis of Time 83

4.5.1 Total Time Completion and Comparison of GFA / Time of

Project 83

4.5.1.1 Total Time Completion and Comparison of GFA/

time of Project for Steel Formwork System 84

4.5.1.2 Total Time Completion and Comparison GFA/ time

of Project for Block Works System 86

4.5.1.3 Total Time Completion and Comparison GFA/ time

of Project for Precast Concrete Frame, Panel and Box

System 88

4.5.2 Overall Comparison of Average GFA / Month for

IBS 90

4.6 Conclusion 92

CHAPTER 5 CONCLUSION AND RECOMMENDATION 97

5.1 Introduction 97

xii

5.2 Summary 97

5.3 Problem Facing During The Research 99

5.4 Suggestions and Recommendations 99

REFERENCE 101

xiii

LIST OF TABLE

TABLE NO. TITLE PAGE

Table 2.5.3 IBS systems classification based to relative weight of 27

component.

Table 3.4 Cost of Project for Each Elements 57

Table 4.2 Backgrounds of Nine Projects That Used IBS 61

Table 4.3 The Various Types Of IBS Used By The Nine Projects 64

Table 4.3.1 Component of Building Constructed By IBS 65

Table 4.4.1 Total Cost of Project and Cost / m2 for Nine Projects 67

Table 4.4.2.1 Breakdown Cost of Element and Cost/m2 for Steel

Formwork‟s Project 69

Table 4.4.2.2 Breakdown Cost of Element and Cost/m2 for Block Work

System‟s Projects 71

Table 4.4.2.3 Breakdown Cost of Element and Cost/m2 for Precast Concrete

Framing, Panel and Box System‟s Project 73

Table 4.4.3.1 Comparison Cost/m2 of Element for Steel Formwork‟s Project

76

Table 4.4.3.2 Comparison Cost/m2 of Element for Block Work System‟s

Projects 78

Table 4.4.3.3 Comparison Cost/m2 of Element for Precast Concrete

Framing, Panel and Box System‟s Projects 80

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Table 4.4.4 Overall Average Cost/m2 for All IBS Project 81

Table 4.5.1. Total Time Completion and the GFA/time of Project 83

Table 4.5.1.1 Total Time Completion and GFA/time of Project for Steel

Formwork System 84

Table 4.5.1.2 Total Time Completion and GFA/time of Project for Block

Work System 86

Table 4.5.1.3 Total Time Completion and GFA/time of Project Precast

Concrete Framing, Panel and Box System 88

Table 4.5.2 Average GFA/Month for All Type IBS Project 90

xv

LIST OF FIGURE

FIGURE NO TITLE PAGE

Figure1.8 Flowchart of Organization Research 8

Figure 2.5 Classification of IBS system. 23

Figure 2.7 (I) Precast Concrete Slab 33

Figure 2.7(II) Steel Formwork for Wall 34

Figure 2.7 (III) Steel Frame Structure 35

Figure 2.7 (V) Interlocking Brick System 36

Figure 3.2 Research Flow Chart 55

Figure 4.3 The Various Types of IBS Used By Five Projects 64

Figure 4.4.2.1(a) Breakdown Cost of Elements for Steel Formwork System‟s

Projects 69

Figure 4.4.2.1 (b) Cost / m2 of Element for Steel Formwork System‟s

Projects 70

Figure 4.4.2.2 (a) Breakdown Cost of Elements for Block Work System‟s

Projects 71

Figure 4.4.2.2 (b) Cost / m2 of Block Work System‟s Projects 72

Figure 4.4.2.3 (a) Breakdown Cost of Element for Precast Concrete

Framing, Panel and Box System‟s Projects 74

xvi

Figure 4.4.2.3(b) Cost / m2 of Element for Precast Concrete

Framing, Panel and Box System‟s Projects 75

Figure 4.4.3.1 Comparison Cost/m2 of Element for Steel Formwork‟s

Projects 77

Figure 4.4.3.2 Comparison Cost/m2 of Element for Block Work System‟s

Projects 79

Figure 4.4.3.3 Comparison Cost/m2 of Element for Precast Concrete

Framing, Panel, and Box System‟s Projects 80

Figure 4.4.4 Overall Average Cost/m2 for All IBS Project 82

Figure 4.5.1.1(a) Total Time Completion of Project for Steel Formwork

System 85

Figure 4.5.1.1(b) Comparison of GFA/time for Steel Formwork System‟s

Projects 85

Figure 4.5.1.2 (a) Total Time Completion of Project for Block Work

System 87

Figure 4.5.1.2(b) Comparison GFA/time of Project for Block Work

System 87

Figure 4.5.1.3 (a) Total Time Completion of Project for Precast Concrete

Framing, Panel , and Box System 89

Figure 4.5.1.3(b) Comparison GFA/time of Project for Precast Concrete

Framing, Panel and Box System 89

Figure 4.5.2 Average GFA/Month for All types IBS Project 91

xvii

LIST OF ABBREVIATION

ABBREVIATION FULL NAME

CIDB Construction Industry Development Board

IBS Industrialized Building Systems

GFA Gross Floor Area

WBLFF Work Below Floor Finishes

xviii

LIST OF APPENDIX

APPENDIX TITLE

Appendix A Document Analysis Form

1

CHAPTER 1

INTRODUCTION

1.1 Background of Study

The concept of Industrialized Building System (IBS) is not new and can be

traced back to as early as 1624 when penalized timber houses were shipped from

England to the new settlements in North America. While steel structures of road

and railway bridges were common in pre-independence Malaya. The IBS is an old

technology in developed country s such as European and American country but it

is considered as the new technology in developing country in Asia region especially

Malaysia (Noorisah Abd Shukor, 2007) .

The IBS system start gain popularity in 1998 when Cabinet of Ministers

endorsed IBS Strategic as the blue print for total industrialisation of construction

sector .( Zanawi, 2009).Soon, The use of pre-cast concrete in the total construction

industry arrived much later when Construction Industry Development Board

Malaysia (CIDB) was promoting the IBS system in 2003. The CIDB has

implemented the IBS Road Map (2003-2010) to encourage and promote more

people using IBS system.

2

The importance of IBS systems was highlighted under the Construction

Industry Master Plan 2006-2015 which is based on 5-M Strategy (Man Powers,

Materials-Components-Machines, Management-Process-Method, Monetary and

Marketing). The purpose of this master plan was to guide the future of Malaysian

construction industry to achieve the Vision of 2020. By applying the IBS system,

it can create situation which lead our construction industry into high productivity

and efficiency. At the same time, it also can contribute the economic benefits to

Malaysian in the future. IBS is far beyond prefabricated solutions and project

implementation. IBS is also about the changing of the conventional mindset,

championing human capital development; developing better cooperation and trust

and most importantly it is high integrity (Sazali Che Amat, 2003).

Despite well documented benefits and strong support from the Government,

the participating of IBS was not high as first anticipated at this stage. Perhaps cost

and time could be the causes of this problem. Although the members of the

industry are open to the idea, but some of major portion of industry stakeholders are

indifferent, perhaps due to resistance towards change and insufficient fund and

information to support the feasibility of change to implement IBS construction. In

November of 2008, the Treasury of Malaysia had warned all the Government

agencies to increase the IBS contents of their building projects to a level of not less

than 70 points of IBS score and IBs must incorporated as part of the contract

document for tender. ( Sazali Che Amat, 2011). Besides that, the private project

also play important role. The private developers need to participate the IBS to

ensuring this program me is successfully implement.

3

1.2 Issues

According to IBS Road Map 2003-2010 (2003), it has been reported only 15%

of overall construction projects in Malaysia used IBS system. IBS Mid Term Review

in 2007 showed only 10% of completed projects used IBS in the year 2006 as

compared to forecasting IBS usage of 50% in 2006 and 70% in year 2008.

The inadequate of IBS manufacturing plant also one of the reason lead to this

issue. There are few IBS manufacturing plant in Northen Penisular Malaysia,

Western Penisular .Malaysia and Borneo Malaysia. The number of plant still very

limited and the location is mostly in Klang Valley. So with limited of plant, some of

the contractor and developer still stick with the conventional method. (IBS Road

Map 2003-2010, 2003),

Instead of that, lacking of IBS knowledge among the developers and

contractors also contributed to this problem, where there are cases that contractor is

using the IBS for construct the building project but in the end, the project delays and

the cost is hiking. This has make the others think that IBS is difficult to adapt and

cannot solve the construction problems.

Many small contractors are reluctant to adopt IBS system and prefer to

continue using the conventional method of construction. This is due to the fact that

small contractors are already familiar with the conventional system and for them the

technology suit well with small scale projects and therefore not willing to switch to

mechanized based system.

In the perspective of components‟ manufacture, IBS construction requires

high initial investment capital for pre-casters to purchase new machinery, mould,

importing foreign technology and wages of skilled workers for installation process

4

(Thanoon et al. 2003). IBS is also unattractive choice due to wide swing of housing

demand, high interest rate and unsure economic condition (Thanoon et al. 2003).

As a result, the industry viewed IBS as threats to their business and not as

opportunities (Noorisah Abd Shukor, 2007). It appears that existing procurement and

contracting system is not „favourable‟ to both pre-caster and contractor which using

IBS method. The inadequate of IBS manufacturing plant also one of the issues that

will not courage them to use the IBS system.

1.3 Problems Statement

Although the IBS system was introduce since two decade ago, but it seems

like still cannot gain very high popularity among the contractors and developers.

From the issues that had been highlighted, it can be summarized that limited

manufacturing plant of IBS caused the project cost increase. Some manufacturing

plants are far away from project location caused the project delay. Insufficient

knowledge about IBS especially the type of IBS and its components to be used on the

project. Without used the appropriate type of IBS and its component on the project

can caused the cost hiking and delayed the project.

To solve these issues, few research questions have come out for this research.

The first question is what types of IBS system provided in our country and the

second question is what is the different cost and time among the various type of IBS

system?

5

1.4 Research Questions

For this research, there are some questions have been identified as follow :

1. What type of IBS systems frequently practice in Malaysia?

2. What are the different cost and time among the various types of IBS

systems for high rise building like apartment and condominium?

1.5 Objective of Study

My objective study will be as follow:

1. To identify the various type of IBS systems used in Malaysia

2. To evaluate the cost and time of the various type of IBS systems for

apartments and condominiums building.

1.6 Significant of Study

From this study, it provides a brief and clear idea to construction

professionals like contractor, Architect, and QS about the effectiveness on cost and

time for the various types of IBS systems. With the information that obtained from

the case study, we can determine how effectiveness cost and time on various types of

IBS systems based on the project Gross Floor Area. From that, construction

6

professionals and other parties that involved can try to determine some ideas,

strategies or solution and some necessary actions to overcome this problem.

1.7 Scope of Study

This study is mainly focus on the effectiveness on cost and time for the

various types of IBS systems. The types of IBS that I targeted are Precast Concrete

Framing, Panel, and Box Systems, Steel Formworks, and Block Work System. The

reason is those three types of IBS are frequently used in our country. My targeted

project is apartment and condominium projects that are used the IBS. There will be

three projects for each type of IBS, the total of projects for my research are nine

projects. More information will be collected through construction journals,

magazines, books and newspapers, articles, and website.

1.8 Methodology Research

There are several methods I‟m using in order to find relevant information to done

this report. Among the methods are:-

Through library sources

Library is a very wide resource for us to search for everything. I often visit the UTM

library, Perpustakaan Sultanah Zainab (PSZ) to look for information and data for my

research. There are many book and journal resources for my references. In library,

7

not only books, magazines, and journals that I can borrow, there are also store the

previous theses that I can refer to look for information.

Through construction magazines and newspapers

I read it every day and concern of what has happen to construction industry

nowadays, what are the problems faced and the solutions done by the government

and private sector. From there, I know what the problems I face and what are

resources or solution to overcome my problems.

Through case study.

Data and information from the books and internets look limited and not enough to

support my research. So the case study will be conducted through selected

contractors firms, developer firms and consultants firms that have involve in any IBS

projects to get more information and data to support my research.

8

1.9 Organisation Research

Figure1.8: Flowchart of Organization Research.

THE EFFECTIVENESS OF COST AND TIME FOR

VARIOUS TYPES OF IBS SYSTEM

Objectives

To compare the cost and time for

the various types of IBS system

To identify the various type of IBS

system

Research Methodology

CASE STUDY

Data Analysis

Conclusion

9

My research will be divided in to five main parts, which are shown below:

Chapter 1: Introduction

This is the first part of my research, it‟s a brief introduction about the title research

will be shown in this chapter.

Chapter 2: Literature Review

In this chapter, it‟s all about the secondary data. Secondary data mean information

and data come from books, magazines, journals, articles, conference, and so on. All

the information are related to the various types of IBS system and comparison cost

and time for various types of IBS system.

Chapter 3: Research Methodology

This chapter will discuss about the method of research. This are included case study

method.

Chapter 4: Data Analysis

In this chapter, data collection from document study will be transform into table,

graph and pie chart. The analysis will be carried out based on the previous data and

also the current statistics.

10

Chapter 5: Conclusion and Recommendation

The last chapter of the research, an overall conclusion will be made after the

finalizing data. Several suggestions will be made in order to improve the current

situations.

CHAPTER 2

EFFECTIVENESS OF COST AND TIME FOR THE VARIOUS TYPE OF IBS

SYSTEMS

2.1 Introduction

The Professional Journal of Surveyors Malaysia, 2008, stated that since

decades ago, the pressure to deliver construction projects at a high speed, lower cost

and high quality has grown. Clients are now virtually demanding that consultants and

contractors deliver the project in half the time as was used to. On a positive note, this

severe level of expectation has accelerated the prominence and implementation of

IBS in the Malaysian construction industry. Nevertheless, the innovative natural of

IBS itself requires a different set of approach and procedures for it to progress and be

substantially attractive to a wider audience. As a result, the need to accurately

estimate the cost of IBS projects has grown more urgent and important. The main

reason is because usually there is no feasible time to re-scope and IBS project since

cost, efficiency and the economies of scale are inseparable determinants. Client and

construction professionals must be cognizant to the cost implication of any design,

specification or scheduling change throughout the entire project development process.

12

2.2 Definition of IBS

According to Nor Azmi et al (2008), IBS is acknowledged in many writings

as a construction method that has many advantages especially on aspects of

construction management. IBS can be defined a system that use industrial production

techniques either in the production of components or assembly of the building, or

both. It is a system where the design and structure of the building are reduced to a set

number of common constituent parts or components, with the rationale that they can

be prefabricated or manufactured in low-term production runs, even far away from

construction site. These components, furnished with standard dimension and

specified attributes, will then be delivered to the site and assembled according to

certain standards in order to bring together the proposed building.

Zuhairi Abd Hamid ( 2012) defined IBS as a construction technique in which

components are manufactured in a controlled environment (on or off-site),

transported, positioned and assembled into a structure with minimal additional site

works. As such, components that are being pre-fabricated in a controlled

environment on-site are also considered as IBS. While there are numerous

descriptions of the Industrialised Building Systems (IBS) concept by local

researchers, all of the definitions stressed on pre-fabrication and mass production.

According to Warswaski (1999), the industrialised building system (IBS) can

be defined in which all building such as wall, slab, beam, column and staircase are

mass produced either in factory or at site factory under strict quality control and

minimal wet site activities. Industrialisation process is an investment in equipment,

facilities and technology with the objective of maximising production output,

minimizing labour resource and improving quality while a building system is defined

as a set 10 of interconnected element that joint together to enable the designated

performance of a building.

13

Warswaski (1999) also explained that an industrialisation process is an

investment in equipment, facilities, and technology with the objective of maximising

production output, minimising labour resource, and improving quality while a

building system is defined as a set of interconnected element that joint together to

enable the designated performance of a building.

IBS also can be defined as construction systems in which components are

manufactured in a factory, on or off site, positioned and assembled into a structure

with minimal additional site works (Shahrul Nizaar Shaari, 2003). The word

„building‟ in the IBS term relates to „constructing‟ and therefore covers all type of

structures, not only for buildings construction. It is a products, system and techniques

used in making construction less labour-oriented, faster than and as well as quality

controlled (Warswaski 1999).

Perhaps the most comprehensive definition of IBS is IBS in the construction

industry includes the industrialised process by which components of a building are

manufactured transported and erected on site and managed to produce lean

construction. The system includes a balanced combination between the software

and hardware components.

The hardware elements are categorised into three major groups which

includes frame system, panel system, and box or modules system. Meanwhile the

software elements include system design, market analysis, development of

standardised components, establishment of manufacturing and assembly layout and

process, allocation of resources and materials and definition of a building designer

conceptual framework (Warswaski 1999).

14

2.3 Precast Concrete

Nor Azmi et al, (2008) has stated the precast reinforced concrete components;

whether fashioned on-site or prefabricated at a distant factory, considered as IBS.

Based on the book of Donald Friedman, (2010), the use of precast reinforced-

concrete units in construction was a logical extension of the use of “off - site

prefabricated” steel, timber, and masonry units. Structure materials were

manufactured, brought to the site, and then installed, as the labors just need to apply

finishing such as plastering and painting. The difference between casting concrete on

site and installing the precast concrete lies in the form of the building in question. A

traditional bearing-wall building could be built substituting precast concrete beams

for wood joist with an increase in strength and safety, since the connection of the

beam to the walls consists of gravity bearing. By contrast, a concrete building meant

to replace a steel skeleton-frame building has to be constructed in a way that replace

a steel skeleton-frame building has to be constructed in a way that replaces the lateral

bracing of the frame, with rigid joints between members or some other form of

bracing.

Both promoters and opponents generally agreed on the advantages and

disadvantages of precast construction, differing only on how important the various

factors were. The advantages include lower costs from moving most skilled labor

from the site to the factory, from a reduced amount of formwork and shoring, and the

ability to perform much of the work during poor weather that would normally halt on

site casting. Another advantage that was not overtly economic was the better quality

control achievable during factory casting. The most serious weakness was the

difficulty in creating rigid and continuous connections between the separate precast

sections. The natural condition of precast sections are as individual pieces designed

to work separately, which is closer to steel construction than cast-in-place reinforced

concrete but without the ability to easily create rigid connections that riveting

allowed in steel. This flaw not only made it difficult for designers to achieve overall

15

stability, but also made the individual sections weaker than the equivalent cast-in-

place sections. (Donald Friedman , 2010).

2.4 Pre-Fabrication Technology

According to Kelly (1951), pre-fabrication can be defined as a modern

method of construction technology that had been introduced in our country for the

past decades ago. Pre-fabrication is a construction method largely rely on

standardized manufactured components in a factory or other manufacturing site.

Once it completed, it will be transporting to the construction site where the structure

is located. This technology is used to be a different characteristic of method of

conventional construction by transporting the materials to the construction site where

all assembly is carried out.

Since our country construction industry growth rapidly, it become clear that

how important the uses of pre-fabrication to influence the developers and contractors.

This term bring so much effect to the design of building as the marketing sales and

financing increasing upon the good design. Therefore, the prefabricators will bring in

more expert staff or retain the service and management in order to deal with the

problem that will face in the future. The theory behind this technology is time and

cost can be saved if similar construction tasks or projects be grouped together,

and same technique and method can be employed in prefabrication at a location

where skilled labour is available, while spending long time casting in-situ on site can

be reduced. Prefabrication avoids the necessary of many skilled workers at the

construction site, and other limitation condition such as a lack of power, lack of

material, or exposure to extreme weather are avoided (Kelly, 1951).

16

2.4.1Classification of Pre-Fabrication System

Generally, there are two most popular basis of classification can be

categorized in pre-fabrication system, by materials and by structural system (Kelly,

1951).

Materials Structural System

Figure 2.4: The Classification of Pre-fabrication System.

Classification of Pre-fabrication System

Frame

Steel

Aluminum

Concrete

Plastics

Wood

Frame Panel

Stressed Skin

Panels

Solid Panels

Poured at Site

17

2.4.2 Materials

Materials play a very important role in choices and adaptability to the

prefabricator‟s pattern of operations and for customers or clients satisfaction and

requirements. Most of the special quality required by clients in materials make by

prefabricators being light weight, strength, wearing quality, adaptability to normal

fabrication and transportation methods, and low cost as well. There are four types of

material that usually used by prefabricators, wood, steel, aluminum, concrete and

plastics. (Kelly, 1951),

2.4.2.1 Wood

Nowadays, wood can be categorized as one of most important structural

material in construction industry and also used by largest group of prefabricators.

The type of the wood usually used by most of the construction is plywood whereby it

brings a large influence on the growth of prefabrication as a whole. This material is

very light and strong, extreme stiff, has some insulation value, comes in large sheets

readily adapted to mass-production uses, has fairly good dimensional stability, and is

reasonably durable and low in cost. Plywood has some several functions can be

combined. Example, a single sheet can be both surface and structural sheathing on

the outside, or both surface and wallboard on the inside (Kelly, 1951).

18

2.4.2.2 Steel

Steel is considered as a basic manufacturing material in our country

construction industry. Most of the time, the steel is used for manufacture of low cost

housing. Prefabricators normally used steel as a basic material in their structure.

With this, they used steel in combination with wood and aluminum. Steel still has

some disadvantages in housing design. Its thermal conductivity is more than 300

times of wood so that more attention must to be paid to problem heat loss and

condensation. Steel easily get rust so it must be carefully protected from contact with

oxidizing atmospheres and this automatically increase the cost (Kelly, 1951).

2.4.2.3. Aluminum

Aluminum is one of the major structural materials. It can be form as framing

or exterior structural covering. Many prefabricators are interested of it because it is

easy to get and most importantly the price is cheap compare to steel and wood.

Aluminum has certain advantages for housing purposes, including a positive value as

reflective insulation and a strong resistance to serious corrosion under normal

atmospheric conditions. Aluminum is suited to many construction industry

techniques although it can be welded only with some difficulty and must be formed

with careful attention to its properties (Kelly, 1951).

19

2.4.2.4. Concrete

Sometime, prefabricators consider wet-process materials unsuited to

mass production methods, although there are exceptions, as when such special

fabrication machines are introduced. Yet, there are still many companies still using

concrete to form precast concrete slabs. Concrete may have distinct advantage over

other materials in original materials cost, but its disadvantages of weight, bulk, and

frangibility have limited its use primarily to group erections close to the production

points of the slabs (Kelly, 1951). Pre-stressed concrete shows promise of achieving

two or three times the strength of ordinary concrete with the same weight of material

and its being more generally used in the construction industry, but all these still

concern by prefabricators.

2.4.2.5. Plastics

Plastics are an ordinary material in construction industry. However, it was

doubt by prefabricators to use as a major structural material. In part, this was

undoubtedly the result of the high cost of most plastics, now and in the foreseeable

future, but there is also evidence that the structural properties of most plastics are

inferior to those of wood, steel, concrete and aluminum. Laminated phenolics, the

most seriously considered of the plastics as a structural material, have three or four

times greater strength in compression than in tension, which make it difficult to

justify using so expensive material in tension as a working skin. The plastics industry

is at work on these problems, and such new materials as glass fiber reinforced show

promise (Kelly, 1951).The major structural use for plastics, however, remains in the

bonding of plywood and other built-up structural materials.

20

2.4.2.6 Structural System

In building construction, the structural system is most important major

element so that it can support and transmit applied loads safely to the ground without

exceeding the allowable stresses in the members. Basic types of systems

include bearing-wall, post-and-beam, frame, membrane, and suspension. For the

frame, it can be sub-divided into five types, Frame Assembly, Frame Panels, Stressed

Skin Panels, Solid Panels and Poured at Site.

2.4.2.7 Frame Assembly

The typical frame assembly is the conventional wood frame house, in the

course of construction of which individual framing members are erected at the site

and various insulting and finishing materials then applied. The precut lumber house

is an example of a fabrication system embodying frame assembly principles (Kelly,

1951).

2.4.2.8 Frame Panels

In this classification, the structural members are preassembled in the form of

panels, and some or all of the insulting and finishing materials are usually applied in

the shop in order to save time at the site. The wall panel produced by what may be

called the typical prefabricator is a frame panel, made up of framing lumber with

wood sheathing nailed to it.

21

2.4.2.9 Stressed Skin Panels

According to Kelly, (1951), where the panels are so designed and assembled

that the surfacing elements contribute in a major way to the structural performance of

the whole, it‟s called as a stressed skin panel. A stressed skin action is partially

obtained by the use of a single surface material bonded securely to the structural

framing and by this means developing some stiffness and strength at the contiguous

surfaces. Most of the construction having single factory-applied surface are not

securely enough bonded to develop this added strength. There have been some

attempts to approach a monocoque system of construction, but requirements for

opening and difficulties with single pre-stressed shell. Stressed skin design used to

reduce the amount and weight of materials. It has a better chance to adapt well to

mass-production industrial processes.

2.4.2.10 Solid Panels

The example for solid panel is the precast concrete slab, which is essentially

homogeneous throughout. There are reinforce steel and laminated panels with

plywood or asbestos cement facings involved, where major structural resistance to

load is channeled into skin or reinforcement, the panels should perhaps logically be

place under other structural system. But where the panel is fabricated as a solid entity

(excluding honeycomb core materials), and where all parts of the panel assume major

structural roles, the designation of solid panels has been used (Kelly, 1951).

22

2.4.2.11 Poured at Site

Kelly,(1951) has stated this system includes essentially monolithic structures

in which the emphasis in the pre-fabrication system tends to fall as much upon the

pouring and forming machinery as upon the house itself. This system specially

designed to make concrete pouring and forming operations at the site efficient and

economical, have recently been regarded with a great deal of interest of interest in

this country. A factor in this interest has been the recent rapid expansion of the

development of lightweight concretes, offering easier handling, better surface

qualities, far better thermal properties, and a faster casting cycle than the regular

concretes, while retaining sufficient strength to be self-supporting and avoid the

necessity of added framing or skins.

2.5 Classification of IBS Systems

According to Warszwazaki, (1999), the IBS systems can be classified into 3 main

aspects :

I. Classification according to structural system.

II. Classification according to material.

III. Classification according to relative weight of component.

23

Figure 2.5 :Classification of IBS system.

2.5.1 Classification According to Structural System

Based on Warszwazaki (1999), there are three categories IBS can be

classified in this structural system aspect. There are:

I. Linear system or frames (beams and column)

II. Panel System

III. Rectangular or Boxes system or Three dimensional system

2.5.1.1 Linear System or Frames (beam and column)

CLASSIFICATION OF IBS SYSTEMS

Structural System Relative Weight of

Component

Material

24

According to Warszwazaki (1999), linear system or frame is system that use

column and beam as the main structure member where columns and beams support

all the building weight. The walls need to be light and easy to be installed and

concrete panels are introduced as flooring element.

2.5.1.2 Panel System

In the opinion of Warszwazaki (1999), the panel system is the most widely

used types of prefabricated system those employing panel-shaped elements for floor

slabs, vertical support, partition, and exterior walls. This system maybe prefabricated

with a considerable amount of finish work – exterior finish, thermal insulation,

electrical conduits, window, frame and others. Most of this system often used in

residential building, for example: office, schools, hotels and other similar buildings

with moderate loads and large amounts of finish works.

2.5.1.3 Rectangular or Boxes system or Three Dimensional System

This boxes system functioned as the main building elements, it is a box unit

that contain concrete walls and floors. The unit can be either cast in box like molds

or assembled in the plan from panel elements. In both cases, they can contain a

substantial amount of finish works – walls and floor finish, electrical wiring an

fixtures, painted and glazed doors and window, plumbing pipes and fixtures and so

on.

2.5.2 Classification According to Material

25

The materials classification for IBS systems can be categorized four types,

timber, bricks and block works, steel, and reinforce concrete.( Jaspal Azam et al,

2009)

2.5.2.1 Timber

There are two types of prefabrication of timber which is ready-cut plus shop

fabrication of joints (column and beam) and structural panels where there are only

walls and floors without column and beam.

2.5.2.2 Bricks and Block Works

The bricks or blocks are manufactured and carried out in a mass at factory

and transported to site or onsite of the building under construction in the form of

panel and then erected Warszwazaki (1999).

2.5.2.3 Steel

Steel construction normally contains factors of prefabrication which is one of

the criteria of IBS. Steel is an element jointed by welding, riveting or bolting on site.

The large proportion of the strength from steels capable to support the weight of

structure building and allows a long-span or high-rise building (Warszwazaki ,1999).

2.5.2.4 Reinforced concrete

26

Reinforced concrete has high degree of availability, low material cost,

durability, and fire resistance. In reinforced concrete, the tensile strength of steel and

the compressive strength of concrete work together to allow the member to sustain

these stresses over considerable spans.(Warszwazaki ,1999).

2.5.3 Classification According to Relative Weight of Components

The IBS components can be classified according to their relative weight as in

Table 1. According to Thanoon cited Majzub, (1977), the relative weight of

components should be used as a basis for building classification due to the factor of

weight has significant impact on the transportability of components and has influence

on the production method of the components and their erection method on site.

27

Table 2.5: IBS systems classification based to relative weight of component. ( Thanoon cited

Mazjub, 1997).

2.6 Characteristics of IBS Systems

According to (Warszawski, 1999), The main features of an industrialised

building system are as follows:

No. General System Systems Production Materials

1. Frame System Light weight frame Wood, light gage metals.

Medium light weight frame Metal, reinforce plastics, laminated wood.

Heavy weight frame Heavy steel, concrete.

2.

Panel System

Light and medium weight

panel

Wood frame, metal frame, and composite

materials.

Heavy weight panel (factory

manufactured)

Concrete.

Heavy weight panel (tilt up –

produced on site)

Concrete.

3.

Box System

(modules)

Medium weight box (mobile) Wood frame, light gage metals,

composite.

Medium weight box

(sectional)

Wood frame, light gage metals,

composite.

Heavy weight box (factory

manufactured)

Concrete.

Heavy weight box (tunnel

produced on site)

Concrete.

28

i. As many of the building elements are prefabricated offsite, at a central facility,

where specialized equipment and organization can be established for this purpose.

ii. The various building works are incorporated into large prefabricated assemblieswi

th minimum erection, jointing and finishing work onsite.

iii. Materials and component handling onsite is extensively mechanized; in concrete

work, large standard steel forms, ready-mixed concrete, and concrete pumps are used.

iv. Design, production, and erection onsite are strongly interrelated. They must bevie

wed therefore as parts of an integrated process which has to be planned and

coordinated accordingly.

Industrialised Building System has its own characteristics which are differ

itself from convention method. There are characteristics of Industrialized Building

System are (CIDB, 2001):

i. Industrial production of components though prefabrication; or highly mechanized

in-situ processes

ii. Reduced labour during prefabrication of components and site works.

iii.Modern design and manufacturing methods which has the involvement of

Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).

iv. Systematic Quality Control such as ISO 9000 principles.

29

v. Open Building concept where it is permitting hybrid applications, adaptable to

standardization and Modular Coordination (MC).

2.6.1 Essential Characteristics of IBS Systems

There are some necessary characteristics underlining the successful

implementation of industrialised building system. The characteristics are briefly

explained at below.

2.6.1.1 Closed System

According to (Warszawski,1999), a closed system can be classified into two

categories, namely production based on client‟s design and production based on pre-

caster‟s design. The first category is designed to meet a spatial requirement of client,

that is the spaces required for various functions in the building as well as the specific

architectural design. In this instance, the client‟s needs are paramount and the pre-

caster is always forced to produce a specific component for a building. On the other

hand, the production based on pre-caster‟s design includes designing and producing a

uniform type of building or a group of building variants, which can be produced with

a common assortments of component. Such building includes school, parking garage,

gas station, low cost housing, etc. Nevertheless these types of building arrangement

can be justified economically only when the following circumstances are observed :

a) The size of project is large enough to allow for distribution of design and

production costs over the extra cost per component incur due to the specific design.

30

b) The architectural design observes large repetitive element and standardisation. In

respect to this, a novel prefabrication system can overcome the requirement of many

standardised elements by automating the design and production process.

c) There is a sufficient demand for a typical type of building such as school so that a

mass production can be obtained.

d) There is an intensive marketing strategy by pre-caster to enlighten the clients and

designer the potential benefit of the system in term of economics and noneconomic

aspects.

2.6.2 2Open System

In view of the limitations inherent in the closed system, an open system

which allows greater flexibility of design and maximum coordination between the

designer and pre-caster has been proposed. This system is plausible because it allow

the pre-caster to produce a limited number of elements with a predetermined range of

product and at the same time maintaining architectural aesthetic value. ( Thannon

cited Trikha,1999)

Based on ( Thannon cited Trikha,1999), in spite of many advantages inherent

in an open system, its adoption experiences one major setback. For example, joint

and connection problem occur when two elements from different system are fixed

together. This is because similar connection technology must be observed in order to

achieve greater structural performance.

31

2.6.3 Standardisation and Tolerances

For accomplishing the requirement of modular co-ordination, all components

need to be standardised for production. Such standardisation of space and elements

need prescribing tolerances at different construction stages such as manufactured

tolerances, setting out tolerances, and erection tolerances, so that the combined

tolerance obtained on statistical considerations is within the permitted limits

( Thanoon cited Trikha,1999).

Production resources can be used in the most efficient manner if the output is

standardised. Then the production process, machinery, and workers‟ training can be

best absorbed to the particular characteristics of the product (Thanoon, 2003).

2.6.4 Specialisation

According to (Warszawski, 1999), large production output and

standardisation of precast elements allow a high degree of labour specialisation with

the production process. The process can be subdivided into a large number of small

homogenous tasks. In such working condition, workers are exposed to their work

repetitiously with higher productivity level.

2.6.5 Good Organisation

High production volume, specialisation of work, and centralisation of

production requires a efficient and experiences organisation capable of a high level

32

of planning, organising, coordination and control function with respect to production

and distribution of the products (Warszawski, 1999).

2.6.6 Integration

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 (Warszawski, 1999).

2.6.7 Equipment at Site

For the purpose of erecting and assembling precast panels into their position,

heavy crane is required especially for multi-storey building. It is therefore important

to incorporate this additional cost when adopting a prefabrication system

(Warszawski, 1999).

2.7 Type of IBS

According to CIDB, IBS Centre, (2003), Industrialised Building System (IBS)

is a technique of construction whereby components are manufactured in a controlled

environment, either at site or off site, and transported, positioned and assembled into

construction works. There are five main IBS groups identified in Malaysia, there are:

33

I. Precast Concrete Framing, Panel and Box Systems

Precast concrete elements are the most common IBS type.

There are precast concrete columns, beams, slabs, walls, lightweight

precast concrete, and permanent concrete formworks. Beside, it is also

consist of 3D components such as balconies, staircases ,toilets, lift

chamber, refuse chambers and others.

Figure 2.7 (I) : Precast Concrete Slab (CIDB,2010)

II. Steel Formwork Systems

This system generally involved site casting, and therefore

subjected to structural quality control. So, it is considered as the “low

level” or the “least prefabrication” IBS types. However, this system

does offer high quality finishes and fast construction with less site

34

labour and material requirement. These include tunnel forms, tilt-up

systems, beam and columns moulding forms and permanent steel

formworks like metal decks.

Figure 2.7 (II): Steel Formwork For Wall (CIDB,2010)

III. Steel Framing Systems

This system commonly used with precast concrete slabs, steel

columns and beams have always been the popular choice and used

extensively in the fast-track construction of skyscrapers. Recent

development in this type of IBS includes the increased usage of light

steel trusses. It is consisting of cost-effective profiled cold-formed

channels and steel portal frame systems as alternatives to the heavier

traditional hot-rolled sections.

35

Figure 2.7 (III) : Steel Frame Structure (CIDB,2010)

IV. Timber Framing Systems

This system is including timber building frame and timber roof

truss. While timber roof truss systems are more popular, timber building

frame systems also have its own niche market where it is offering

interesting designs from simple dwelling units to buildings requiring high

aesthetical values such as chalets for resorts.

V. Blockwork Systems

This system includes interlocking concrete masonry and

lightweight concrete blocks.

36

Figure 2.7 (V) : Interlocking Brick System (CIDB,2010)

2.8 Benefits of IBS

Kamarul, Ghani, Charles Egbu & Mohammed Arif, (2010) had mentioned

there are several aspects of IBS that has the potential of contributing benefits to

construction industry Some of the major aspects are explained below:

i. Sustainability from Controlled Production Environment

IBS offers a controlled manufacturing environment with the ability to reach

difficult nooks and corners, which are often inaccessible in regular in-situ

construction. With the availability of production tools, and permanent jigs and

fixtures, it is easier to control the workmanship of construction, ensuring a tighter

construction resulting in lot lesser energy loss due to leakages (thermal leakage).

37

ii. IBS and Waste

IBS traditionally has been known to minimize waste, with the ability to reuse

material from one module or product into another, the sustainability agenda is

supported through its use. However, several aspects of planning both in terms of

materials management and production management have to be monitored in order to

achieve the waste minimization benefits promised by IBS.

iii. IBS and Building Materials

Several pre-fabricated technologies such as Structural Insulated Panels (SIPS)

offer great potential in terms of fabrication of more energy efficient buildings [18].

However, if appropriate process control and planning are not implemented these

potential benefits could be lost due to expensive on-site assembly processes.

Therefore, it is important that the advent of new technologies should be accompanied

by proper process design for on-site assembly.

iv. IBS and Logistics

Some estimates recently have put the amount of environmental impact from

material transportation activities to be one-third of total environmental impact on the

entire construction process. IBS offers another benefit, and that is the ability to order

in large quantities thus reducing the number of trips to be taken. Despite this

potential benefit, it is important that a detailed material transportation and logistics

plan be put in place.

38

v. IBS and Economic Sustainability

With Malaysian government‟s emphasis on reduction of reliance on foreign

labour, and the ability of IBS to deliver to this goal is well documented. However,

for this to succeed there is the need to develop a detailed training and dissemination

strategy for promoting IBS and preparing the workforce for that.

2.9 IBS Implementation

According to Zawawi,(2009), Implementation stage caries largest scale of

project life cycle including variety of physical work such as design, fabrication work

at factory, logistics task (example: transportation, supply chain management, vendor),

installation and erection work at site, and commissioning.

In the other words, there are several activities of implementation which can

be categorized as upstream activities and downstream activities. Upstream activities

can be list as design, planning and production works. On the other hand, procurement

system, supply chain, transportation system, legislation and regulation can be

classified as downstream activities in implementing IBS. Different activities of a

project can proceed subsequently with different speeds in design and consequent

stages, but all must come together in testing and commission stage for the finish

building.( Zanawi et al, 2009)

39

2.10 Promotion of IBS in Malaysia

According to Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and

C.M Tham, (2001), Construction Industry Development Board of Malaysia

(CIDB),Kementerian Perumahan dan Kerajaan Tempatan (KPKT), and the Public

Institution of Higher Learning (IPTA) are currently championing the IBS promotion.

To achieve this, a concept of coordination of dimension and space in which buildings

and components are dimensioned and positioned in terms of basic unit or module is

being introduced and known as Modular Co-ordination (MC). The introduction of

MC in the industry is to improve productivity and quality in building as well as to act

as a tool towards rationalization and industrialization of the building industry.

MC provides a practical approach towards achieving the following objectives

( Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001):

I. The establishment adoption of a dimensional system agreeable to all

parties;

II. Rationalisation of traditional or conventional approach in building design;

III. To promote the development towards an open building system; and

IV. To facilitate the development of a cataloguing system for building

components.

CIDB together with KPKT and IPTA have developed a number of

strategies for the effective introduction and implementation of MC in the

industry. Every player in the industry would have roles to play to help the MC

be successfully implemented. (Salihuddin Radin Sumadi , Johnson W.K. Ng,

S.L. Sim and C.M Tham, 2001).

40

Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M

Tham, (2001) also mentioned CIDB has designed a series of courses with the

objectives of training and exposing the participants to the basics of MC.

Advanced MC courses have been designed for those who presently submit

drawings to the local authorities. These courses would provide opportunities

for the submitting person to be registered by CIDB as a qualified person in MC

and thus, given permission to use MC mark in their drawings.

To professionally execute these courses, CIDB has collaborated with

a numbers of professional institutions and industrial associations. They will

provide the facilities and infrastructures for the courses. Further training

options and services offer would be made known to their target audience.

(Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001)

Strategies for the implementation of MC were formulated as follows

(Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001):

a) Promotion of building components that conforms to MS 1064 through

MC Certification Scheme,

b) Enforcement through Uniform Building by-laws by Local Authorities;

c) Provide intensive training to all players of the construction industry,

especially those directly involved in the MC, e.g. Submitting Person,

manufacturer, contractor, and others.

d) Promotion of MC to all relevant parties in the industry, and

e) Implementation of MC pilot projects.

41

Meanwhile, CIDB through Construction Research Institute of

Malaysia (CREAM) is set to be the center for information on R&D for the

construction sector. This service ensures that information gathered by CREAM

is delivered or available for the construction industry. Promotion of research

products through publication in scientific journals, CREAM journals, bulletin

or report will be useful industry resource. (Salihuddin Radin Sumadi , Johnson

W.K. Ng, S.L. Sim and C.M Tham, 2001)

2.11 Roadmap Towards Making IBS A Success In Malaysia

Instead of identified the barriers to the introduction of IBS in the

country, Salihuddin Radin Sumadi , Johnson W.K. Ng and Salman Ullah

Sheikh, (2003) have suggest some measures, which would facilitate adoption

of IBS in the country. The following measures are discussed below (Salihuddin

Radin Sumadi , Johnson W.K. Ng and Salman Ullah Sheikh, 2003):

I. Implementation of Modular Coordination (MC)

Dimensional rules for manufacturing of modular parts of all kinds are

the key to a higher productivity of the construction industry, hence, reduced

costs. Modular coordination is about efficiency in industrial production to

coincide with high activities in the building industry and reduced wastage.

Hence, it would definitely reduce the cost of construction by a big margin. This

in the end will benefit the end users, especially houses buyers, enabling them to

purchase property at a relatively cheaper cost and with higher quality of

workmanship.

42

II. Policies

Policies should be drafted in ways which will encourage the use of

IBS in the local construction scene.

a) State Intervention and Stipulations

The government needs to recognize the advantages, which accrue

from adoption of IBS. These not only improve the speed of construction,

hence it can meeting the targets of house construction as made out in its

national plans, affordability, quality of construction which assures a life

span of at least 50-60 years, indoor comfort, and social acceptability. To

gain these advantages, it is very important for government proclaim the IBS

to be the common practice for building construction.

b) Reconstructing of The Building Industry

The building industry ought to do the same and restructure itself into

conglomerates and giant players to be able to undertake mega projects without

the assistance of foreign consultants. It will become immediately clear to the

reconstructed industry that conventional building practices, which are short on

technology and heavy on labor, must be abandoned, and that innovations in

materials, building components and building systems are ultimately more suited

in the charged scenario. It will be easily realized that capital investment in

automation in production of elements and in erection will pay ultimately

dividends which are beyond expectations. Such restructuring will not obliterate

the need for small players but these small players will be undergoing a radical

43

wholesome transformation to fit in with the requirements of mega projects and

the big industry players.

c) Manufacturing Facilities For Prefab Components

The MC dimensioning would permit standardization of building

components with permitted tolerance for manufacture. Different options for

prefab elements would emerge for different building systems. Thus for frame

construction, prefab beams and for different story construction, prefab columns

of different heights with integrated brackets would be required. In panel

construction, possibilities of prefab solid or sandwich panels exist. The panels

could be full sized or only partial, with or without openings. Precast mortar less

elements using interlocking blocks could be devised. Precast parts for roof

trusses could be become assemblies for the complete roofs. Full sized slabs or

precast RC planks, which could be handled manually, would make the floors.

In order to cater the enormous demand created for prefab elements of

different types and cost and labor saving measures, manufacturing industries

would have to resort to automation in production and manufacturer of

elements. The financial institutions and the government policies are thus

needed to provide for the initial capital investment in setting up such

industries and import of appropriate machinery.

44

III. Research and Development (R&D)

R&D is a must in the construction industry even though many

perceive the industry to be a matured industry, which is incapable of

utilizing new ideas and technology.

a) Information and Dissemination

It is estimated that is the last 5 years, 10% or about RM 10 billion

have been lost in construction industry due to poor information management

amongst the industry players like suppliers, contractors, architects and

designers. The Information Management & Dissemination System (IM&DS)

will be a special purpose software controlling and dissemination mechanism

coordinating all construction aspects like material procurement sources,

component manufacturers, standard prefab elements, standards architectural

plans for DIY house construction, cost analysis and instructions for self-help

construction. The system will be accessible through internet to potential users.

Mega corporations could have additional modules to include tendering process,

sales and loan schemes, maintenance schedules and the like. Such elaborate

IM&DS will play a crucial role in propagating the use of IBS on a vast scale in

the country.

b) Industry R&D Linkages

No imported IBS can cater to the socio-economic constraints of individual

countries. This is especially true in case of west originated IBS, as there are vast

45

differences in social and cultural values and in climate and ground conditions. There

is thus a great compulsion for indigenization of imported IBS and the development of

indigenous IBS is justified for more than just economic considerations. This is

possible only if strong linkages between industry and research centers are created. As

today, research centers can only provide basic scientific back up and novel ideas of

innovations in materials and components. Prototyping the laboratory ideas into pilot

production and viable erection and assembly procedures require not only

considerable financial inputs which are beyond the capacity of the research centers

but also require a constant evolutionary approach synergizing with the vast

experience of the building industry.

c) Benchmarking

A benchmarked practice needs to be established for performance

measurement. Increasingly, the major clients are seeking assurances from

contracting organisations that they are using a process of continuous

improvement within their company. Clients normally seeking long term

partnership contractors to assured the project performance and quality. Similar

requirements also form an important feature of many quality management

systems. The benchmarking initiative can provide a major role in delivering

these requirements in an objective manner.

IV. Human Resource

By having a comprehensive training and accreditation system in place,

our erectors, fabricators, installers and supervisors can be trained in the various

aspect of modular construction such as handling, erection, jointing and safety

procedures. On a similar note, our engineers and architects can also be trained to

handle this technology by introducing IBS syllabus in the institutions of higher

learning (IPT). Our present syllabus, for an example concentrates heavily on in-situ

46

construction, with only marginal attention towards construction involving

prestressed , precast or prefabricated elements. A paradigm shift can also be

brought about in the thinking of practicing engineers and architects by encouraging

the Institute of Engineers (IEM) and Association of Architects (PAM) to have more

seminars and talks on the merits of modular construction.

V. Construction Management

From construction manager‟s point of view, the contract document,

the conditions of contract and the tender document should be drafted in such a way

that emphasizes and facilitates or at least allows the use of modular construction.

Plans and drawings using this type of construction should obtain speedy approval

from various bodies such as the Municipal Council and Fire Department.

2.12 Construction Cost

Dobson (2004), has mentioned the construction cost is one of the

hardest element in project management. Cost can be divided into seven parts or

components in a project construction, the seven of cost components are

(E.Haynes,1992):

I. Labor – The wages paid to all staff directly working on the project for

the time spent on it.

47

II. Overhead – The cost of payroll taxes and fringe benefits for everyone

directly working on the project for the time spent on it. Usually

calculated as a percentage of direct labor cost.

III. Materials – The cost of item purchased for use in the project. Includes

such things as lumber, cement, steel, nails, screws, rivets, bolts, and

paint.

IV. Supplies – The cost of tools, equipment, office supplies, etc., needed for

the project. If something has a useful life beyond the project, its cost

should be prorated.

V. Equipment rental – The cost of renting equipment such as scaffolding,

compressors, cranes, bulldozers, trucks, etc., for use on the project.

VI. General and Administrative – The cost of management and support

services such as purchasing, accounting, secretarial, etc., for time

dedicated to the project. Usually calculated as a percentage of project

cost.

VII. Profit – In a for-profit project, the reward to the firm for successfully

completing the project. Usually calculated as a percentage of project

cost.

Project management is directly managed and control expenses and the cost

involved. Application of IBS will save labor costs compared to the conventional

method. Intensive mechanical equipment and minimal use of skilled labor can reduce

48

30-40 percent of the cost of the work. Instead of reduce the uses of timber formwork

and the reinforcement steel, IBS also directly minimize the waste costs at site.

(Trikha dan Abang Abdullah, 2004)

2.13 Cost Control

The purpose of cost control are (Kerzner H,2003) :

I. Limitation provisions provided by the client.

II. Produce a design that fits the existing provisions

III. The concept of money for value, value engineering and buildability to get

optimal cost for a project.

2.13.1 Importance of Cost Control

Ashworth A. (2004), stated the importance of cost control are:

I. That the provision is not lost and exceeds the original amount.

II. To control design changes and scope of the planned project early.

III. Maximize profit margins for the contractor.

IV. Control of the waste material and double handing works.

49

2.14 Time and Duration of Project

Time in the context of the construction industry can be described as referring

to the time involved during the process of development through construction

activities. Project is unique, one of the characteristics of the project is start and end

time. For completion time should be emphasized during construction activities.

Generally, the work activities can be made by scheduling or programs with data

detailing work such as critical path method (CPM), Ghant cart, PERT and others

(Brian Cooke and Peter William., 2009). Trikha dan Abang Abdullah (2004) stated

the completion of time by using the IBS method is 70% faster than conventional

method. Short period of time driven by IBS panel system installation is simple and

quick with the use of machinery mechanisms (Modul Pengurusan System IBS CIDB,

2010).

2.15 Time for Completion

Most standard condition of contract has similar provisions as regards time

completion and somewhere in the contract will be stated (Brian Cooke and Peter

William, 2009):

Date for possession of the site.

Date(s) for possession of specific sections of the site. (where appropriate)

Date for completion of the works.

Date(s) for completion section(s) of the works.

50

Time periods for deferment of possession may also be stated so that the

employer may delay handling over the site to the contractor without breaching the

contract. The contract will usually state the agreed rate of liquidated and ascertained

damages (LAD) for the whole, or where applicable, sections of the works, so that the

employer may charge the contractor in the event of late completion of contract (Brian

Cooke and Peter William, 2009).

2.16 Conclusion

Industrialized Building Systems (IBS) or off-site construction has been

introduced to cope with a growing demand of affordable housing, solving issues

associated with foreign workers and improving image, quality and productivity of

construction related services in Malaysia. IBS can be a strategic move for the local

construction industry to further up the value chain, transforming it into a service

industry that deals with components manufactured in factories.

CHAPTER 3

RESEARCH METHODOLOGY

3.1 Introduction

Research methodology is a method that could be applied to get the data and

information in the research that will be conducted. In the other word, it is defined as

a methodological process to search, collect, identify, and valuation the data for

analysis purpose. This may need a proper plan, systematic, and good understanding

before conduct the research. Thus, the research methodology is important for this

research to achieve the objective and purpose of this study.

3.2 Research Process And Procedure

This research can be divided into five stages, 1) Identify the problems and

research objective, 2) Literature review, 3) Data collection, 4) Data analysis and 5)

Conclusion and recommendation.

53

3.2.1 Identify The Problems and Research Objective

This is the first stage of beginning of the research, whereby I need to find out

the problems and issues based on some reading and understanding towards the

articles, newspapers and journals about the effectiveness on cost and time for various

types of IBS issues. Then, I determined the research question based on my problem

statements and formulated and developed it as questionnaire and interview questions

on my research methodology.

3.2.2 Literature Review

The main purpose of literature review is to collect more information from this

secondary data. The secondary data mean the data or information about various types

of IBS systems that can obtain from books, articles, magazines, journals, some

electronic source like internet, e-books, and websites. Most of this source can be

found at UTM and Built Environment Faculty library. With more information and

data, it can make me more understand my research objective.

3.2.3 Data Collection

Data collection can be collected from two sources, primary data and

secondary data. Primary data can obtain from case study. For this research, a study

has been conducted on contract documents of nine same types of project from

different companies. The documents are Bill of Quantities (BQ) of the project that

contains the cost of project and the time completion of project. The secondary data is

based on the literature review in chapter 2.

54

3.2.4 Data Analysis

This part is the most important part in the research whereby analysis on the

research based on appropriate statistical method from the data collection. For the

case study, documents in the form of oral and writing can become one of the best

research data. Therefore, a case study is conducted on contract document and

architectural drawings to abstract out the data. It can provide important information

and data about the study subject experience that will be very useful for this research.

3.2.5 Method of Analysis

The method of analysis that used for this research is Descriptive Statistics.

This method used to describe the basic features of the data in a study. This method

can provide simple summaries about the sample and the measures. Together with

simple graphics analysis, it can form the basis of virtually every quantitative analysis

of data.

3.2.6 Conclusion and Recommendation

After the analysis of data, a conclusion on the finding will be made for this

research to identify the various types of IBS systems and comparison of the cost and

time for the various types of IBS system.

55

Figure 3.2 Research Flow Chart

3.3 Research Sampling

The term „sample‟ means a specimen or part of whole (population) which is

drawn to show what the rest is like. Research sampling is something that used and

chooses to collect data for our purposed of the study.

Base on this research, the research sampling that has been use for the study

are contract documents and Architecture drawings based on different type of IBS

systems. The BQ and architecture drawings can obtain from contractor firms and

Problems Statement

Identify Objectives

Literature Review

Data Collection

Primary Data Secondary Data

Data Analysis

Conclusion & Recommendation

Stage 1

Stage 2

Stage 3

Stage 4

Stage 5

56

developer firms that have been involved in any IBS project. Nine completed projects

that consist of various type of IBS system had been obtained .and will be undergoing

analysis process to abstract the data.

3.4 Research Instrument

The research instrument for this research is conducted document analysis on

the contract documents to get the project and its element cost. The document analysis

also conducted on architecture drawing to get the project gross floor area. Because

the contract documents and the architecture drawings are private and confidential,

hence a document analysis form has been designed in order to abstract the data out

from the contract documents and drawings that has been study.

The way to design a relevant survey form is very important in order to obtain

the intended and adequate information from those IBS project. For the document

analysis form, it will be divided into 3 sections. The first section can be project

background, the second section will be types of IBS system apply by those project,

the third section will be the cost and time information for the completed IBS project.

3.4.1 Section 1: Project Background

This section contains the information of project name, project location, type

of project and gross floor area of project. Company stamp and signature also required

and compulsory for certify my research.

57

3.4.2 Section 2: Types of IBS System Apply by Project

For this section, I will identify which type of IBS system is apply by those

project. Then I also will indicate which component or element is done by IBS system.

3.4.3 Section 3: Cost and Time Information of IBS Project

This part consists of the cost and time information for those IBS project.

From the BQ that I obtain, I can abstract the breakdown element cost of project and

total time complete of project. Then I only calculate the cost per GFA and time

complete per GFA. Here is the sample of the breakdown element cost of project:

Cost Information

Table 3.4: Cost of Project For Each Elements

(RM)

Preliminaries

WBLFF

Frame

Upper Floor

Roof

Wall

Finishes

M & E

External Works

TOTAL COST OF PROJECT

58

Cost of Project/ Gross Floor Area (GFA) m2: _____________/m2

Time Information

a) Time completion of project: ____________months

b) Gross Floor Area/ month : _____________

3.5 Data Collection

Data collection is considered as a main research tools or preliminary or

supplement to the other methods when doing a research study. For this research, the

collection of data is used the quantitative method, that is case study in order to

achieve the objectives. Case study method can be described as a very useful method

that can allow the participants to analyses a real-life situation. In addition, it can give

a real and clear picture of to participant and make the research become more realistic.

3.6 Data Analysis

Data analysis means to transform a raw data into a meaningful information

that can be used or to illustrate something that can help to achieve research

objectives. Data analysis involves categorizing, scheduling and compiling evidence

acquired through data collection. For this research, the type of analysis is document

59

analysis. The document analysis has been done on the three projects for each type of

IBS system of Bill of Quantities and architecture drawings in order to get out the cost

and the gross floor area. Hence, comparison on cost and time of element project from

various type IBS will be done to find out which type IBS has the most effectiveness

on cost and time.

60

CHAPTER 4

DATA ANALYSIS

4.1 Introduction

In this chapter, researchers are focusing on the analysis on the data obtained in the

data collection stage. Due to the type of research are based on case studies, therefore, the

analysis conducted in this chapter is focused on the following projects that used the IBS

where it will be used as case studies.

This analysis is conducted based on my research objective to be achieved that is

to identify the various types of IBS systems that had been use by the contractor or

developer and to compare the cost and time among the various types of IBS systems

where this comparative study will be conducted as a whole and specifically in accordance

with the work items involved.

In the end, this research able to show the lowest cost / m2 of IBS and the fastest

speed of IBS.

61

4.2 Projects Background

The table below explained the backgrounds of nine of the same type projects

that used the IBS.

Table 4.2: Backgrounds of Nine Projects That Used the IBS.

The table above showed the backgrounds of nine projects that used the IBS.

The Project 1 is type of apartment building which is located at Kota Bharu, Kelantan

state. The owner of this project is SBJ Binajaya Development Sdn Bhd. This

PROJECT

NO.

CONTRACTOR/DEVELOPER TYPE OF

BUILDING

GFA (M2)

1 SBJ Binajaya Development

Sdn Bhd

Apartment 5,360

2 FNA Builders & Services Sdn

Bhd

Condominium 28,480

3 Ambang Rahmat Resource Apartment 8,361

4 Kim Lun Sdn Bhd Condominium 21,580

5 Setia Precast Sdn Bhd Apartment 87,062

6 Setia Precast Sdn Bhd Apartment 69,205

7 Ambang Rahmat Resources Apartment 6,255

8 IDE-Totalap Joint Venture Apartment 21,496

9 IDE-Totalap Joint Venture Condominium 7,620

62

apartment consisted 1 block of 6 floor building with 80 units. The total Gross Floor

Area for the whole apartment is 5,360 m2 or 893.33 m2 for each floor of the building.

For the Project 2, it is categorized as condominium, house where it is located

at Puchong, Selangor state. The owner of this project is FNA Builders & Services

Sdn Bhd. There are 2 blocks of 16 floors condominium consisted 220 units and 2

units of luxury pent house on top of building. The total Gross Floor Area of this

project is 28,480 m2 or 890 m2 for each floor of building.

The type of building for the Project 3 is 1 block of 5 floors of service

apartment. The project is built at Semenyih, Kajang, Selangor state. The owner of

this project is Ambang Rahmat Resource, a contractor company. This project make

of 50 units of house and the Gross Floor Area for this project is 8,361 m2.

For the Project 4, the type of building is condominium. The project is located

at JB Centre, Johor Bahru, Johor state. The owner for this project is Kim Lun Sdn

Bhd. The project make of 2block of 15 floor condominium, consists of 300 units

house and the Gross Floor Area for this project is 21,580 m2.

The type of building for the Project 5 is apartment building. The project is

located Setia Alam, Shah Alam, Selangor state. The owner for this project is Setia

Precast Sdn Bhd, also known as SP Setia Bhd Group. There are 6 block of apartment

for this project and consist 948 units houses. The Gross Floor Area for this project is

87,061 m2 or 91.84 m2 for 1 unit of apartment house.

63

The Project 6 is a block 32 storey of services apartment which has 482 units

houses. The owner of this project is Setia Precast Sdn Bhd and it located at Tebrau,

Johor Bahru, Johor. The Gross Floor Area for this project is 69,205 m2.

For the Project 7, the type of building is a block of 15 storey services

apartment which consists 150 units houses. The contractor for this project is Ambang

Rahmat Resources and the location of this project is at Setapak Jaya, Kuala Lumpur.

The Gross Floor Area for this project is 6,255m2.

The Project 8 is a block of 2 floor apartments with 2 floor of car park and 68

units of house. The contractor for this project is IDE-Totalap Joint Venture and

location of this project is at Tanjung Bungah, Pulau Pinang. The Gross Floor Area

for this project is 21,496 m2.

Last, the type of building for the Project 9 is a block of 10 floor condominium

which has 50 units of house. The project is built by the IDE-Totalap Joint Venture

and the project is located at Batu Ferringi, Pulau Pinang. The Gross Floor Area for

this project is 7,620 m2.

4.3 Types of IBS Used By The Projects

The table and figure below explained the different types of IBS that has been

used by the nine projects.

64

Table 4.3 : The Various Types Of IBS Used By The Five Projects.

Figure 4.3 : The Various Types Of IBS Used By The Five Projects.

The Table 4.4 and Figure 4.4 showed the three types of IBS used by the nie

projects which categorized under the same type of projects, apartment and

0 1 2 3 4

PRECAST CONCRETEFRAMING, PANEL AND

BOX SYSTEMS

STEEL FORMWORKS

BLOCK WORK SYSTEMS

VARIOUS TYPES OF IBS

TOTAL NO. OF IBS SYSTEMS

TYPE OF

IBS

PRECAST

CONCRETE

FRAMING, PANEL

AND BOX

SYSTEMS

STEEL

FORMWORKS

BLOCK WORK

SYSTEMS

PROJECT 1 1

PROJECT 2 1

PROJECT 3 1

PROJECT 4 1

PROJECT 5 1

PROJECT 6 1

PROJECT 7 1

PROJECT 8 1

PROJECT 9 1

TOTAL 3 3 3

65

condominium building. Project 4 , Project 5 and Project 6 are used the Precast

Concrete Framing, Panel And Box Systems. Meanwhile, Project 1 , Project 2 and

Project 9 used the Steel Formwork system. Lastly, the Project 3, Project 7 and

Project 8 is used the Block Work System.

4.3.1 Component of Building Constructed By IBS

Table 4.3.1 : Component of Building Make By IBS

The table above showed the components of building constructed by the IBS.

For the Precast Concrete Framing, Panel and Box Systems from Project 4, Project 5

and Project 6, the building components that the projects used are the precast concrete

beams and columns for the frame element, while for the slabs, its built by the solid

panels, also known as precast concrete slab. For the walls, its built by precast

concrete wall panel. For the staircase, it built by precast concrete staircase.

For the Steel Formwork from Project 1, Project 2 and Project 9, the building

components that the projects used are the concrete beams, columns, slabs, walls and

TYPE OF IBS COMPONENTS

PRECAST CONCRETE FRAMING, PANEL AND

BOX SYSTEMS Beams, columns, slabs, walls, &

staircases.

STEEL FORMWORKS Beams, columns, & walls.

BLOCK WORK SYSTEMS Beams, columns, & walls.

66

staircases which used the permanent steel formwork to cast on site. Considered as

least prefabrication IBS types but high quality finishes.

For the Block Work Systems from the Project 3, Project 7 and Project 8, the

building components that the project used are the columns, beams, slabs, walls and

staircases which used the interlocking bricks to build. The interlocking bricks are

made from manufactory and send to site construction to install.

4.4 Analysis of Cost

4.4.1 Total Cost of Projects and Cost / Gross Floor Area

The table and figure explained the total cost of nine same types of

project and its cost per GFA.

67

Table 4.4.1: The Total Cost of Projects and Cost / m2 for Nine Projects

PROJECT

NO

TYPE OF IBS TOTAL COST

(RM)

GFA

(M2)

RM/M2

PROJECT 1 STEEL FORMWORK 14,773,500 5,360 2756.25

PROJECT 2 STEEL FORMWORK 48,780,000 28,480 1712.78

PROJECT 9 STEEL FORMWORK 12,317,223 7,620 1616.43

PROJECT 3 BLOCK WORK SYSTEMS 11,646,000 8,361 1392.90

PROJECT 7 BLOCK WORK SYSTEMS 11,081,500 6,255 1771.62

PROJECT 8 BLOCK WORK SYSTEMS 18,878,951 21,496 878.25

PROEJCT 4 PRECAST CONCRETE

FRAMING, PANEL AND BOX

SYSTEM

26,017,200 21,580 1205.62

PROJECT 5 PRECAST CONCRETE

FRAMING, PANEL AND BOX

SYSTEM

81,401,000 87,062 934.98

PROJECT 6 PRECAST CONCRETE

FRAMING, PANEL AND BOX

SYSTEM

65,607,019 69,205 948.01

The Table 4.4.1 showed the total cost of projects and cost / Gross Floor Area

of nine projects for the various types of IBS which are abstract from the document

contract. There are three projects for each type of IBS. The projects that used Steel

Formwork system are Project 1, Project 2 and Project 9. For the Project 1, the total

cost of project is RM 114,773,500 and for the cost /Gross Floor Area is RM 2,756 /

m2. Next, the total cost of Project 2 is RM 48,780,000 and for the cost / Gross Floor

Area is RM 1,712 / m2. Then, for the Project 9, the total cost of project is RM

12,317,223 and the cost / Gross Floor Area is RM 1,616/m2.

Meanwhile, the projects that are used the Block Work System are Project 3,

Project 7 and Project 8. The total cost for Project 3 is RM 11,081,500 and the cost /

Gross Floor Area are RM 878 / m2. Next, the total cost for Project 7 is RM

11,081,500 and the cost / Gross Floor Area is RM 1771 /m2. Then, the total cost for

the Project 8 is RM 18,878,951 and the cost / Gross Floor Area is RM 878 /m2.

68

Project 4, Project 5 and Project 6 are used the the Precast Concrete Framing,

Panel and Box Systems. The total cost of project for Project 4 is RM 26,017,200, the

Project 5 is RM 81,401,000 and Project 6 is RM 65,607,019. The cost / Gross Floor

area for Project 4 is RM 1205 / m2, the Project 5 is RM 934 / m2 and the Project 6 is

RM 948 / m2.

4.4.2 Breakdown Cost and Cost /M2 of IBS Project Elements

Those nine projects are not total 100 percent build by IBS, there are some

elements used the IBS. By breaking down the cost of project elements, the researcher

can find out the cost / m2 of elements for the each type of project. The figure below

show the cost / m2 for each project elements.

4.4.2.1 Breakdown Cost of Element and Cost / M2 for Steel Formwork Systems

The table and figure below explained the breakdown cost and cost /m2 for

Project 1, Project 2 and Project 9 of Steel Formwork System.

Table 4.4.2.1 : Breakdown Cost of Elements and Cost / m2 for Steel Formwork

System‟s Projects.

PROJECT NO PROJECT 1 PROJECT 2 PROJECT 9

ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2

69

FRAME 3,515,000 655.78 15,300,000 537.22 2,076,090 272.45

WALL 1,200,000 223.88 2,750,000 96.56 3,015,000 395.67

TOTAL 4,715,000 879.66 18,050,000 633.78 5,091,090 668.12

The table 4.4.2.1 showed the breakdown cost of elements and cost / m2 for

Steel Formwork System‟s projects which abstract from the document contract. The

cost of each element is divided with the GFA of project in order to get the cost / m2

for each element that used the Steel Formwork System.

Figure 4.4.2.1(a): Breakdown Cost of Elements Steel Formwork System‟s Projects.

The figure 4.4.2.1(a) showed the breakdown cost of element for Steel

Formworks System‟s projects. For the Project 1 the cost of element frame is RM

3,515,000. Meanwhile, for the element walls, the cost is RM 1,200,000. The total

cost of all elements for Project 1 is RM 4,715,000. Then, for the Project 2, the cost

for the element frame is RM 15,300,000 and for the element walls, the cost is RM

2,750,000. The total cost of all elements for Project 2 is RM 18,050,000. For the

Project 9, the cost of the element frame is RM 2,076,090 and for the element walls,

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

16,000,000

FRAME WALL

3,515,000

1,200,000

15,300,000

2,750,000 2,076,090

3,015,000

PROJECT 1 RM

PROJECT 2 RM

PROJECT 9 RM

70

the cost is RM 3,015,000. The total cost of all elements for Project 9 is RM

5,091,093.

Figure 4.4.2.1 (b): Cost / m2 of Element for Steel Formwork System‟s Projects.

The figure 4.4.2.1 (b) showed the cost / m2 of element Steel Formwork

System‟s Projects. For Project 1, the cost / m2 for element frame is RM 655.78 / m2

and the cost / m2 for the element wall is RM 223.88 / m2. The total cost / m2 for all

elements is RM 879.66 / m2. Then, the cost / m2 of the element frame for the Project

2 is RM 537.22 / m2 and the cost /m2 of the element walls is RM 1055.48 / m2. The

total cost / m2 of element is RM 633.78/m2. For the Project 9, the cost / m2 of

element frame is RM 272.45 / m2 and the cost / m2 of the element wall is RM

395.67 / m2. The total cost / m2 for all elements is RM 668.12 / m2.

0.00

100.00

200.00

300.00

400.00

500.00

600.00

700.00

FRAME WALL

655.78

223.88

537.22

96.56

272.45

395.67 PROJECT 1 RM/M2

PROJECT 2 RM/M2

PROJECT 9 RM/M2

71

4.4.2.2 Breakdown Cost and Cost / m2 of Element for Block Work Systems

Below is the table and figure showed the cost and cost / m2 of element for

Block Work System‟s projects.

Table 4.4.2.2 : Breakdown Cost of Elements and Cost / m2 for Block Work

System‟s projects.

PROJECT NO PROJECT 3 PROJECT 7 PROJECT 8

ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2

FRAME 2,344,000 280.35 1,602,900 256.26 3,577,506 166.43

WALL 2,620,000 313.36 1,050,100 167.88 1,362,306 63.37

TOTAL 4,964,000 594 2,653,000 424 4,939,813 230

The table 4.4.2.2 showed the breakdown cost of elements and cost /m2 for

Block Work System‟s projects which abstract from document contract. The cost of

each element is divided with the GFA of project in order to get the cost / m2 for each

element that used the Block Work System.

Figure 4.4.2.2 (a): Breakdown Cost of Elements for Block Work System‟s Projects.

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

4,000,000

FRAME WALL

2,344,000 2,620,000

1,602,900

1,050,100

3,577,506

1,362,306

PROJECT 3 RM

PROJECT 7 RM

PROJECT 8 RM

72

The figure 4.4.2.2(a) showed the breakdown cost of element for Block Work

System‟s projects. For the Project 3, the cost of element frame is RM 2,344,000 and

for the element walls, the cost is RM 2,620,000. The total cost of element is RM

4,964,000.Then, for the Project 7, the cost of element frame is RM 1,602,900 and for

the element walls, the cost is RM 1,050,100. The total cost of element is RM

2,653,000. Lastly, for the Project 8, the cost of element frame is RM 3,577,506 and

for the element walls, the cost is RM 1,362,306. The total cost of element is RM

4,939,813.

Figure 4.4.2.2(b): Cost / m2 of Elements for Block Work System‟s Projects.

The figure 4.4.2.2 (b) showed the cost / m2 of elements for Block Work

System‟s projects. For the Project 3, the cost / m2 of the element frame is RM 280.35

/ m2 and the cost /m2 for the element walls is RM 313.36 / m2. The total cost / m2 of

element is RM 593.71/m2. Then, for the Project 7, the cost / m2 of the element frame

is RM 256.26 / m2 and for the element walls, the cost / m2 is RM 167.88 / m2. The

total cost /m2 is RM 424.14/m2. Finally, for the Project 8, the cost / m2 of the

element frame is RM 166.43 / m2 and for the element walls, the cost / m2 is RM

63.37 / m2. The total cost /m2 is RM 229.88/m2.

0.00

50.00

100.00

150.00

200.00

250.00

300.00

350.00

FRAME WALL

280.35

313.36

256.26

167.88 166.43

63.37

PROJECT 3 RM/M2

PROJECT 7 RM/M2

PROJECT 8 RM/M2

73

4.4.2.3 Breakdown Cost and Cost / m2 of Element for Precast Concrete Framing,

Panel and Box System.

The table and figure below showed the breakdown cost and cost / m2 of

element for Precast Concrete Framing, Panel and Box System‟s projects.

Table 4.4.2.3 : Breakdown Cost of Elements and Cost / m2 for Precast Concrete

Framing, Panel and Box System‟s Projects.

PROJECT NO PROJECT 4 PROJECT 5 PROJECT 6

ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2

FRAME 4,676,900 216.72 9,746,000 111.94 13,309,474 192.32

UPPER FLOOR 2,250,000 104.26 4,100,000 47.09 3,652,410 52.78

WALL 2,158,000 100.00 16,079,000 184.68 1,215,413 17.56

STAIRCASE 860,000 39.85 520,000 5.97 700,325 10.12

TOTAL 9,944,900 460.84 30,445,000 349.69 18,877,622 272.78

The table 4.4.2.3 showed the breakdown cost of elements and cost / m2 for

Precast Concrete Framing, Panel and Box System‟s Projects which abstract from the

document contract. The cost of each element is divided with the GFA of project in

order to get the cost / m2 for each element that used the Precast Concrete Framing,

Panel and Box System.

74

Figure 4.4.2.3 (a): Breakdown Cost of Elements for Precast Concrete Framing,

Panel and Box System‟s Projects.

The figure 4.4.2.3 (a) showed the breakdown cost and cost/ m2 of element for

Precast Concrete Framing, Panel and Box System‟s projects. For the Project 4, the

cost of element frame is RM 4,676,900. Then, for the element upper floor, the cost is

RM 2,250,000. For the element walls, the cost is RM 2,158,000. Last, the cost of

element staircase is RM 860,000. The total cost of element is RM 9,994,900. Next,

For the Project 5, the cost of element frame is RM 9,746,000. Then, the cost of

element upper floor is RM 4,100,000 and. For the element walls, the cost is RM

16,079,000. Last, the cost / m2 for the element staircase is RM 520,000. Total cost of

element is RM 30,445,000. At last, for the element frame, the cost is RM 13,309,474.

For the element upper floor, the cost is RM 3,652,410 and. For the element walls, the

cost is RM 1,215,413. Last, the cost for the element staircase is RM 700,325. Total

cost of element is RM 18,877,622.

0

2,000,000

4,000,000

6,000,000

8,000,000

10,000,000

12,000,000

14,000,000

16,000,000

18,000,000

FRAME UPPERFLOOR

WALL STAIRCASE

4,676,900

2,250,000 2,158,000

860,000

9,746,000

4,100,000

16,079,000

520,000

13,309,474

3,652,410

1,215,413

700,325

PROJECT 4 RM

PROJECT 5 RM

PROJECT 6 RM

75

Figure 4.4.2.3(b): The Cost / m2 of Element for Precast Concrete Framing, Panel

and Box System‟s Projects.

The figure 4.4.2.3 (b) showed the cost / m2 of element for the Precast

Concrete Framing, Panel and Box System‟s Projects. For the Project 4, the cost / m2

for the element frame is RM 216.72 / m2. For the element upper floor, the cost / m2

is RM 104.26 / m2. Then, the cost / m2 for the walls is RM 100.00 / m2. Last, the

cost / m2 for the element staircase is RM 39.85 / m2. Total of the cost/m2 is RM

460.84. For the Project 5, the cost / m2 of element frame is RM 111.94 / m2. Then,

the cost / m2 for the element upper floor is RM 47.09 / m2. For the element wall, the

cost / m2 is RM 184.68 / m2. Last, the cost / m2 for the element staircase is RM 5.97

/ m2. Total cost/m2 is RM 349.69. At last, for the Project 6, the cost / m2 of element

frame is RM 192.32/ m2. Then, the cost / m2 for the element upper floor is RM

52.78/ m2. For the element wall, the cost / m2 is RM 17.56 / m2. Last, the cost / m2

for the element staircase is RM 10.12 / m2. Total cost/m2 is RM 272.78.

0.00

50.00

100.00

150.00

200.00

250.00

FRAME UPPERFLOOR

WALL STAIRCASE

216.72

104.26 100.00

39.85

111.94

47.09

184.68

5.97

192.32

52.78

17.56 10.12

PROJECT 4 RM/M2

PROJECT 5 RM/M2

PROJECT 6 RM/M2

76

4.4.3 Comparison of Cost / m2 for IBS’s Projects

Every project for each IBS system will be compared by its cost / m2. The

tables and figures below are showed the comparison of cost / m2 for each IBS for the

nine projects.

4.4.3.1 Comparison of Cost / m2 For Steel Formwork

The cost / m2 of each element for Project 1, Project 2, and Project 9 for Steel

Formwork System will be compared with each other to get which of the project get

the highest cost / m2 and the lowest cost / m2.

Table 4.4.3.1:Cost/m2 of Element for Steel Formwork‟s Projects.

PROJECT NO. TOTAL COST/M2 OF ELEMENT

PROJECT 1 RM 879.66 / M2

PROJECT 2 RM 633.78 / M2

PROJECT 9 RM 668.12 /M2

The table 4.4.3.1 showed the total cost / m2of element for Steel Formwork‟s

System‟s projects which consists the additional of total cost of Project 1, Project 2

and Project 9. The cost of element for each project can be refer to the table 4.5.2.1. .

77

Figure 4.4.3.1: Comparison of Cost / m2 of Element for Steel Formwork System.

The figure 4.4.3.1 showed the comparison cost / m2 of three projects for Steel

Formwork. The cost / m2 for the Project 1 is RM879.86 / m2, which is the highest of

cost / m2. Then, the cost / m2 for the Project 2 is RM633.78 / m2, which is the

lowest cost / m2. Last, the cost / m2 for Project 9 is RM668.12 / m2.

The reason that the Project 1 become the highest cost / m2 because this

project used the Circular Steel Formwork to build the circular columns which is

expensive compare to the other two projects used the normal type of steel formwork,

that is Flat Form Panel for build the square columns, beams, floor slab and others.

0.00 200.00 400.00 600.00 800.001000.00

TOTAL COST/M2

879.66

633.78

668.12

PROJECT 9 RM / M2

PROJECT 2 RM /M2

PROJECT 1 RM / M2

78

4.4.3.2 Comparison of Cost / m2 For Block Work System

The cost / m2 of each element for Project3, Project 7, and Project 8 for Block

Work System will be compared with each other to get which of the project get the

highest cost / m2 and the lowest cost / m2.

Table 4.4.3.2 : Total Cost/m2 of Element for Block Work System‟s Projects.

PROJECT NO. TOTAL COST/M2 OF ELEMENT

PROJECT 3 RM 593.71 / M2

PROJECT 7 RM 424.14 / M2

PROJECT 8 RM 229.80 /M2

The table 4.4.3.1 showed the total cost / m2of element for Block Work

System‟s projects which consists the additional of total cost of Project 3, Project 7

and Project 8. The cost of element for each project can be refer to the table 4.5.2.2. .

79

Figure 4.4.3.2: Comparison of Cost / m2 of Element for Block Work System.

The figure 4.4.3.2 showed the comparison cost / m2 of three projects for Steel

Formwork. The cost / m2 for the Project 3 is RM593.71 / m2, which is the highest of

cost / m2. Then, the cost / m2 for the Project 7 is RM424.14 / m2.Last, the cost / m2

for Project 8 is RM229.80 / m2, which is the lowest cost / m2.

The Project 3 get the highest cost /m2 and the Project 8 get the lower cost /

m2 because of the material for walls which Project 3 used Interlocking Brick System

and Project 8 used the Lightweight Masonry Block to build the walls.

0.00 200.00 400.00 600.00

TOTAL COST/M2

593.71

424.14

229.80 PROJECT 8 RM / M2

PROJECT 7 RM / M2

PROJECT 3 RM / M2

80

4.4.3.3 Comparison of Cost / m2 For Precast Concrete Framing, Panel and Box

System

The cost / m2 of each element for Project 4, Project 5, and Project 6 for

Precast Concrete Framing, Panel and Box System will be compared with each other

to get which of the project get the highest cost / m2 and the lowest cost / m2.

Table 4.4.3.3 : Total Cost/m2 of Element for Precast Concrete Framing, Panel and

Box System‟s Projects.

PROJECT NO. TOTAL COST/M2 OF ELEMENT

PROJECT 4 RM 593.71 / M2

PROJECT 5 RM 424.14 / M2

PROJECT 6 RM 229.80 /M2

Figure 4.4.3.3: Comparison of Cost / m2 of Element for Precast Concrete Framing,

Panel and Box System.

0.00 100.00 200.00 300.00 400.00 500.00

TOTAL COST/M2

460.84

349.69

272.78

PROJECT 6 RM / M2

PROJECT 5 RM / M2

PROJECT 4 RM / M2

81

The figure 4.4.3.3 showed the comparison cost / m2 of three projects for

Precast Concrete Framing, Panel and Box System. The cost / m2 for the Project4 is

RM460.84 / m2, which is the highest of cost / m2. Then, the cost / m2 for the Project

5 is RM349.69 / m2.Last, the cost / m2 for Project 6 is RM272.78 / m2, which is the

lowest cost / m2.

The Project 4 has the highest cost / m2 and the Project 6 has the lowest cost /

m2 because of the different type of precast concrete slab. The Project 4 is used the

Precast Concrete Hollow Core Slab which is a unique design of floor slab that can

allow wire go under the slab. The Project 6 is used the Precast Concrete Wide Slab, a

simple design of floor slab for minimum the cost and time.

4.4.4 Overall Comparison Average Cost / m2 for IBS Project

TYPE OF IBS

TOTAL

COST/M2

(RM)

TOTAL

NO.

PROJECT

AVERAGE

COST/M2

(RM)

Precast Concrete Framing ,

Panel and Box System 1083.31 3 361.10

Steel Formwork System 2181.56 3 727.19

Block Work System 1247.65 3 415.88

Table 4.4.4 : Overall Average Cost/m2 for All IBS Project.

The table 4.5.4 showed the overall average cost/m2 for all IBS project. The

total cost/m2 of each type IBS system is divided with the total number of project to

get the average cost/m2 for each IBS system. Then, the average cost/m2 of each IBS

system will be compared to get which type of IBS has the lowest and the highest of

cost/m2.

82

Figure 4.4.4: Overall Average Cost/m2 for All IBS Project.

The table 4.4.4 and figure 4.4.4 showed the overall average cost / m2 for all

type IBS project. For the projects of Precast Concrete Framing, Panel and Box

System, the average cost / m2 is RM361.10 / m2, which is the lowest average cost /

m2 among three type of IBS. Then, the average cost / m2 for Steel Formwork System

is RM727.19 / m2, the highest average cost / m2 among three types of IBS. Last, the

average cost / m2 for Block Work System is RM 415.88 / m2.

Most of the components and the elements of projects of this IBS system are

built by Precast Concrete Framing, Panel and Box System and the components is

fully make at factory before send to the site for the installation .The costs is lower

compare to other IBS system, the Steel Formwork System and Block Work System

because it do not need skilled worker to install this component on the site as the cost

of skill worker is expensive than the non-skilled worker.

0.00

200.00

400.00

600.00

800.00

PrecastConcreteFraming ,Panel and

Box System

SteelFormwork

System

Block WorkSystem

361.10

727.19

415.88

Overall Average Cost/m2 for All IBS Project

AVERAGE COST/M2 (RM)

83

4.5 Analysis of Time

It is very important to know the time completion of project. The purpose is

to know the speed of construction based on its gross floor area over the time of

completion for the nine of same types of project.

4.5.1 Total Time Completion and Comparison of GFA / Time of Project

Table 4.5.1:Total Time Completion and the GFA / time of Project.

PROJECT NO TIME COMPLETION (MONTHS) M2 / MONTH

PROJECT 1 15 357.33

PROJECT 2 26 1095.38

PROJECT 3 12 696.75

PROJECT 4 24 899.17

PROJECT 5 26 3348.54

PROJECT 6 24 2883.54

PROJECT 7 19 329.21

PROJECT 8 24 895.67

PROJECT 9 18 423.33

The table 4.5.1 showed the total time completion and the GFA / time of

project which abstract from the document contract. Then, the GFA/time of project

for each project for every IBS systems will be compared to find the fastest and the

slowest speed of IBS system.

84

4.5.1.1 Total Time Completion and Comparison of GFA/ time of Project for

Steel Formwork System

Table 4.5.1.1:Total Time Completion and GFA/time of Project for Steel Formwork

System.

PROJECT NO. TIME COMPLETION

(MONTH)

GFA (M2) M2 / MONTH

PROJECT 1 15 5,360 357.33

PROJECT 2 26 28,480 1095.38

PROJECT 9 18 7,620 423.33

The table 4.5.1.1 showed the total time completion and GFA/time of project

for Steel Formwork System. The total time completion of Project 1, Project 2 and

Project 9 will be divided with each GFA in order to get the GFA/month.

Figure 4.5.1.1(a): Total Time Completion for Steel Formwork System‟s Projects.

0

5

10

15

20

25

30

PROJECT 1 PROJECT 2 PROJECT 9

15

26

18

TIME COMPLETION(MONTHS)

85

The figure 4.5.1.1(a) showed the total time completion and GFA/ month of

project for Steel Formwork System. The total time completion for Project 1 is 15

months. Then, the total time for Project 2 is 26 months. Finally, the total time

completion for Project 9 is 18 months.

Figure 4.5.1.1(b): Comparison of GFA / time for Steel Formwork System‟s Projects.

The figure 4.5.1.1(b) showed the comparison of GFA / time for Steel

Formwork System‟s projects. For the Project1, the GFA / month is 357.33 m2 /

month, which is the lowest GFA / month. Then, the GFA / month for the Project 2 is

1095.38 m2 / month, which is the highest GFA / month. Finally, the GFA / month for

the Project 9 is 423.33 m2 / month.

0.00

200.00

400.00

600.00

800.00

1000.00

1200.00

PROJECT 1 PROJECT 2 PROJECT 9

357.33

1095.38

423.33 M2 / MONTH

86

4.5.1.2 Total Time Completion and Comparison GFA/ time of Project for Block

Works System

Table 4.5.1.2:Total Time Completion and GFA / time of Project for Block Works

System.

PROJECT NO. TIME COMPLETION

(MONTH)

GFA (M2) M2 / MONTH

PROJECT 3 12 8,361 696.75

PROJECT 7 19 6,255 329.21

PROJECT 8 24 21,496 895.67

The table 4.5.1.2 showed the total time completion and GFA/time of project

for Block Works System. The total time completion of Project 3, Project 7 and

Project 8 will be divided with each GFA in order to get the GFA/month.

Figure 4.5.1.2(a): Total Time Completion Project for Block Work System.

0

5

10

15

20

25

PROJECT 3 PROJECT 7 PROJECT 8

12

19

24

TIME COMPLETION(MONTHS)

87

The figure 4.5.1.2 (a) showed the total time completion and GFA/ month of

project for Block Work System. The total time completion for Project 3 is 12 months.

Then, the total time for Project 7 is 19 months. Finally, the total time completion for

Project 8 is 24 months.

Figure 4.5.1.2(b): Comparison GFA / time of Project for Block Work Systems.

The figure 4.5.1.2(b) showed the comparison GFA/time of project for Block

Work Systems. For the Project 3, the GFA / month is 696.75 m2 / month. Then, the

GFA / month for the Project 7 is 329.21 m2 / month, which is the lowest GFA /

month. Finally, the GFA / month for the Project 8 is 895.67 m2 / month, which is the

highest GFA / month.

0

100

200

300

400

500

600

700

800

900

PROJECT 3 PROJECT 7 PROJECT 8

696.75

329.21

895.67

M2 / MONTH

88

4.5.1.3 Total Time Completion and Comparison GFA/ time of Project for

Precast Concrete Frame, Panel and Box System

Table 4.5.1.3:Total Time Completion and GFA / time of Project for Precast Concrete

Frame, Panel and Box System.

PROJECT NO. TIME COMPLETION

(MONTH)

GFA (M2) M2 / MONTH

PROJECT 4 24 21,580 696.75

PROJECT 5 26 87,062 329.21

PROJECT 6 24 69,205 895.67

The table 4.5.1.3 showed the total time completion and GFA/time of project

for Precast Concrete Frame, Panel and Box System. The total time completion of

Project 4, Project 5 and Project 6 will be divided with each GFA in order to get the

GFA/month .

Figure 4.5.1.3(a): Total Time Completion of Project for Precast Concrete Frame,

Panel and Box System.

23

23.5

24

24.5

25

25.5

26

PROJECT 4 PROJECT 5 PROJECT 6

24

26

24

TIME COMPLETION(MONTHS)

89

The figure 4.5.1.3(a) showed the total time completion and GFA/ month of

project for Precast Concrete Frame, Panel and Box System. The total time

completion for Project 4 is 24 months .The total time completion for Project 5 is 26

months and finally, the total time completion for Project 6 is 24 months.

Figure 4.5.1.3(b): Comparison GFA/time of Project for Precast Concrete Frame,

Panel and Box System.

The figure 4.5.1.3(b) showed the comparison GFA/time of project for Precast

Concrete Frame, Panel and Box System. For the Project 4, the GFA / month is

899.17m2 / month, which is the lowest GFA / month. While, for the Project 5, the

GFA / month is 3,348.54 m2 / month, which is the highest GFA / month. Last, the

GFA / month for the Project 6 is 2,883.54 m2 / month.

0.00

500.00

1000.00

1500.00

2000.00

2500.00

3000.00

3500.00

PROJECT 4 PROJECT 5 PROJECT 6

899.17

3348.54

2883.54

M2 / MONTH

90

4.5.2 Overall Comparison of Average GFA / Month for IBS

The table and figure below showed the average GFA / Month for all type IBS

project.

Table 4.5.2: Average GFA / Month for All Type IBS Projects.

TYPE OF IBS

GFA /

MONTH

TOTAL

PROJECTS

AVERAGE GFA

/ MONTH

STEEL FORMWORK

SYSTEM 401.33 3 133.78

BLOCK WROK SYSTEM 1921.63 3 640.54

PRECAST CONCRETE

FRAME, PANEL AND BOX

SYSTEM 7131.25 3 2377.08

The table 4.5.2 showed the average GFA / month for all type IBS projects

which will be compared with each other to get the speed of construction. To get the

average GFA/month, the total of GFA/month for each type IBS system will be

divided with the total projects. The highest of average GFA/month of IBS is the

fastest speed of construction.

91

Figure 4.5.2: Average GFA / Month for All Type IBS Project.

The table 4.6.2 and figure 4.6.2 showed the average of GFA / Month for all

type IBS projects. The Precast Concrete Frame, Panel and Box System has the

highest average GFA / month, 2377.08 m2 / month, mean that the project that used

this IBS has the fastest speed of construction. Then, the average GFA / month for

Block Work System is 640.54 m2 / month. Last, the average GFA / month for Steel

Formwork is 133.78 m2 / month, which is the lowest average GFA / month. It mean

that the projects used this IBS system has the slowest speed of construction.

The Precast Concrete Frame, Panel and Box System has the highest average

GFA/month or highest speed of construction because the components and elements

are made at factory and direct install on the site without using the skilled workers

compare to other type of IBS systems which using the skilled workers to used it.

0.00 1000.00 2000.00 3000.00

STEEL FORMWORK SYSTEM

BLOCK WROK SYSTEM

PRECAST CONCRETE FRAME,PANEL AND BOX SYSTEM

133.78

640.54

2377.08

Average GFA / Month for All Type IBS

AVERAGE GFA / MONTH

92

4.6 Conclusion

Based on the research analysis that has been done on cost and time overall

projects for the various types of IBS, a very satisfied result has come out. For the

cost, the result showed that the Steel Formwork System has the highest average cost /

m2 that is RM727.19 / m2 and Precast Concrete Framing, Panel and Box System has

the lowest average cost / m2 that is RM361.10 / m2. For the m2 / time of project

completion, the Precast Concrete Framing, Panel and Box System has the fastest

speed of completion project, that is 2,377.08 / month of the average GFA / month

and Steel Formwork System has the slowest speed of completion project, that is

133.78 m2 / month of the average GFA / month. It can be concluded Precast

Concrete Framing, Panel and Box System as the most effectiveness IBS among this

three types of IBS.

97

CHAPTER 5

CONCLUSION AND RECOMMENDATION

5.1 Introduction

Summary of the study will be discussed in this chapter 5 where conclusions

are made based on the results of the analysis in chapter 4. The conclusions made are

covering the entire research that has been conducted on nine of same types of

residential projects that used the IBS has been selected. In this chapter also will

discuss the problems facing during conducting the research. Next, the proposed for

the future research will be suggested in this chapter.

5.2 Summary

In this research, two objectives have been decided so the evaluation towards

the hypothesis can be made. The first objective is to identify the various types of IBS

systems that have been used in Malaysian construction industry. The second

98

objective is to identify the different of cost and time on various types of IBS systems.

The comparison was made and identified based on the cost / gross floor area and

gross floor area / time completion project for every types of project.

For this research, total nine IBS project had been selected. Each IBS have the

three same type of project. There are three projects used Precast Concrete Framing,

Panel and Box System, the Steel Formwork, and the Block Work System.

In order to get the best result of the research, comparison has done on every

three projects of each IBS system to get the average cost / m2 and the GFA / month.

The result of analysis showed the Precast Concrete Framing, Panel and Box System

has the lowest average cost / m2, that is RM361.10 / m2, the Steel Formwork System

has the highest average cost / m2, that is RM727.19 / m2 and the average cost / m2

of Block Work System is RM415.88 / m2. For the time, the Precast Concrete

Framing, Panel and Box System has the highest average GFA / month, that is

2377.08 m2 / month. Then for the Steel Formwork, it has the lowest GFA / month,

that is 133.78 m2 / month. The average GFA / month for Block Work System is

640.54 m2 / month.

At the end of research, the Precast Concrete Framing, Panel and Box System

is the most effective IBS system overall type of IBS system by having the lowest

average cost / m2 and average GFA / month. The result can be proven by looking at

the analysis cost / m2 and m2 / time completion of project.

So, I do really hope in the next future the IBS systems can be practice widely

in our construction industry in addition to aid and fix the weakness of conventional

method of construction.

99

5.3 Problems Facing During The Research

During conducting the research, there are few problems occurs and

complicate the research process. The problems that occurs are :

a) Faced difficulty to find source and data for writing the literature to be

match with the issues.

b) Difficulty to get the documents like BQ and drawing because those

documents are private and confidential.

c) Facing problems when meeting the contractor and developer whose are not

willing to give the cost and time data of project.

5.4 Suggestions and Recommendations

After the research has been done, there are few suggestions of proposal to be

suggested for the future research proposed. The following suggestions are :

1) Analysis The Constructability On Various Type of IBS Systems.

2) Analysis The Risk Management of IBS Systems On Site Construction.

100

3) Compare the Effectiveness Cost, Time and Constructability of IBS

Systems and Green Building Systems.

101

REFERENCE

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APPENDIX A

DEPARTMENT OF QUANTITY SURVEYING

FACULTY OF BUILT ENVIRONMENT

CASE STUDY TITLE:

THE EFFECTIVENESS COST AND TIME ON

VARIOUS TYPES OF IBS SYSTEM.

Objectives:

To identify the various types of IBS system.

To evaluate the cost and time among the various types of IBS system.

This is used to collect data for the study above. All information disclosed will be

treated strictly CONFIDENTIAL and will only be used for academic purposes.

Thank you.

Prepared by:

Goh Tuan Leong (B11BE0010)

900215-03-5213

3SBEQ (Bachelor of Quantity Surveying)

Email: gtleong90@gmail.com

Tel: 013-3114308

Supervisor: Associate Professor Sr Dr Zakaria Mohd Yusof

Company‟s Stamp

Section A

1) Project Background

a) Name of Project: ______________________________________________

b) Project Location : ___________________________________________

c) Type of Project :

Residential Commercial School Factory

Others:___________

d) Gross Floor Area of Project (GFA) :__________________m2

Section B

1) Type of IBS Systems

a) Which type of IBS do the project used?

Precast Concrete Framing, Panel and Box Systems

Steel Formwork Systems

Steel Framing Systems

Timber Framing Systems

Block work Systems

Others __________________

b) Which part/component of building is done by IBS system?

Slabs

Beams

Columns

Walls

Others :____________

Section C

1) Cost Information

a) Breakdown Cost of Project

(RM)

Preliminaries

WBLFF

Frame

Upper Floor

Roof

Wall

Finishes

M & E

External Works

TOTAL COST OF PROJECT

b) Cost of Project/ Gross Floor Area (GFA) m2: _____________/m2

2) Time Information

a) Time completion of project: ____________months

b) Gross Floor Area/ time of complete : ___________m2/ months