CHAPTER 1

CC206 INDUSTRIALISED BUILDING SYSTEM (IBS)

INTRODUCTION OF IBS IN CONSTRUCTION INDUSTRY
Prepared by: UMI HANI BINTI ABDUL RAHMAN Politeknik Merlimau Melaka

Industrialised Building System (IBS)

1. 2. 3. 4. 5. What is IBS? Why IBS? Types of IBS? Challenges Faced by IBS Advantages and Disadvantages of IBS?

1. What is IBS?
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.

1.1 History of IBS

Concept IBS is not new and can be traced back to as early 1624. In 1624, panellised timber houses were shipped from England to the new settlement in North America. 1851 Crystal Palace in Hyde Park, London and 1889 Eiffel Tower, Paris.

Crystal Palace, Hyde Park

During construction 1840

Picture taken in 1851

Eiffel Tower, Paris

During construction 1878

Picture taken in 1945

1.2 History of IBS in Malaysia

Concepts IBS in Malaysia is not new. In 1966 the two pilot project started by using IBS concept. Namely:
Pekeliling Flat, Kuala Lumpur The Rifle Range Flat, Penang

In 1981-1993 PKNS acquired pre-cast concrete technology from Praton Haus International, Germany to built housing project.

Flat Pekeliling, KL

KLIA, Sepang

The Rifle Range Flat, Penang

Public Housing in Nusajaya, Johor

Masjid Besi Putrajaya

Menara Rebung, KL

1.3 Characteristics of IBS

5 characteristics of IBS are:
a) Industrial production of components though prefabrication b) Reduced labour during prefabrication of components and site works. c) Modern design and manufacturing method using CAD/CAM. d) Systematic Quality Control i.e ISO 9000 e) Open Building System i.e permitting hybrid applications

2. Why IBS?
Budget speech 2005

2.1 The current Scenario of Malaysian Construction Industry

This can contributes : Messy sites, High Wastage, Labour Intensive, low quality and delays.

2.2 Social Problems

Currently 75 foreign workers out of 100 construction workers There are 318,000 foreign workers in Malaysian Construction Industry
Let say one foreign worker gain RM400/month RM400 x 12 months = RM5,000/year

318,000 x RM5,000 = RM1.59 Billon/year

It shows the HIGH OUTFLOW OF RINGGIT

3. Types of IBS
In general, the construction method can be classified into 4 categories:
a) b) c) d) Conventional Method Cast-in situ Composite Method Fully prefabricated

Method b, c and d can be classified as non conventional methods and all types of IBSs are categorized under these three.

The construction method can be classified into 4 categories:

 Based on structural aspects, IBS can be divided into 5 major types:

TYPE 1: PRECAST CONCRETE FRAME, PANEL & BOX SYSTEMS

PC columns, beams, slabs, 3D-components (balconies, staircases, toilets, lift chambers, box girders, etc)

TYPE 2: STEEL FORMWORK SYSTEMS

Tunnel forms, beams and column moulding forms, permanent steel formworks (metal decks), etc.

TYPE 3 : STEEL FRAME SYSTEMS

Steel beams and columns, portal frames,roof trusses, etc

TYPE 4: PREFABRICATED TIMBER FRAME SYSTEMS

Timber frames, pre-fab timber roof trusses, etc.

TYPE 5 : BLOCKWORK SYSTEMS

Interlocking concrete masonry unit (CMU), lightweight concrete blocks, etc.

4. Challenges Faced by IBS

Only 15% contractors using IBS, why???
a) Lack of Expertise / Lack of Experience b) Cost 4.1 Lack of Expertise / Lack of Experience a) Lack of experience practicing/designing IBS by the consultants/contractors/clients b) Short of experience workers in the manufacturing and installation works (most of them are foreign workers) c) Detect works by previous pre cast (close system)

d) QS lack of experience pricing the IBS projects (most of them not pricing the total cost of project)

4.2 Cost a) Only 15% contractors using IBS because the low labour cost in this country is the root causes b) Labour cost is cheap

Challenges and Lessons Learn Along the Construction Industry Value Chain
3,252 architects 59.304 engineers 2,081 quantity surveyors 63,977 contractors 118 manufacturers
IBS Value Chain

Designers
Challenges Not a popular choice among designers because IBS perceived as limiting creativity in design Lack of IBS design knowledge among designers Proprietary systems make it hard to be adopted by designer

Contractors / Builders/ Owners

Current exemption from levy cannot cover additional cost for developers Insufficient push factor from the end buyer for IBS properties (except for GoM sector). Unlike Green Buildings where buyers knows the benefits and enjoy tax break for such buildings

IBS Manufacturing Base

Lack of volume and economies of scale due to non-standardisation of designs Lack of quality control in smaller IBS manufacturers Lack of local R&D, support services, technologies and testing labs Lack of innovative products that can enhance aesthetic values of buildings

Construction Site
Lack of on-site specialised skills for assembly and erection of components Lack of people with IBS project management skill which requires more logistics planning & coordination with IBS suppliers (i.e on-time delivery) Additional cost in hiring special equipment and machinery in implementing IBS (i.e heavy duty lifting crane)

The challenges faced have remain unchanged despite being repeatedly voiced by the industry stakeholders during surveys, forums and workshops through-out the yearsindicates problems need to be resolved at the root cause level

Standardisation Issue

Skills Issue

5. Advantages and Disadvantages of IBS

Advantages of IBS
a) Reduction of labor / unskillful workers
When the IBS components are produced in factory, higher degree of utilization of machine is permitted and the use of labor will be reduced and lead to saving in labor cost. It is also will reduce the construction process at site and consequently reduce the number of labor required at site. b) Reduce Wastage The utilization of machine during the production of IBS components lead to higher degree of precision and accuracy in the production and consequently reduce material wastage. Increased in quality An IBS component have higher quality and better finishes due to be careful selection of materials, use of advanced technology, better and strict quality assurance control since production in factory is under sheltered environment. Safe working environment Utilization of IBS components leads to less construction process especially wet work at site. This will lead to the neater site condition and increase safety.

c)

d)

d)

Less construction period (time) IBS requires less construction time because casting of precast element at factory foundation work at site can occur simultaneously and the work at site is only the erection of IBS components. This leads to earlier occupation of the building. Construction less affected by weather Faster project completion due to rapid all weather construction. The effects of weather on construction operation are less due to the fabrication of IBS components is done in factory while at site is only erection of the components. Environmentally friendly The use of IBS will decrease the using of timber formwork on construction projects. Flexibility IBS provides flexibility in the design of precast element so that different systems may produce their own unique prefabrication construction methods. Cost savings The formwork of IBS components are made of steel, aluminums or other materials that allows for repetitive use and this leads to considerable costs savings.

e)

f)

g)

h)

 Disadvantages of IBS
a) Higher initial capital cost The initial capital cost of IBS is usually high. The initial cost including the cost of constructing the factory, casting beds and support machinery. The cost effectiveness can only be achieved when undertaking large projects. Sophisticated plants and skilled operator The prefabrication system relies heavily on sophisticated plants, which have to be well coordinated and maintained by skilled operators. Breakdown in any one section would hold-up the entire production line. Problem of joints Water leakage is often the major problem in building constructed using IBS. This problem is more obvious in Malaysia where raining occur rapidly throughout the year. Large working area Building construction using IBS requires a large working area for the factory, trailers, tower-cranes and storage for the IBS components. Besides, most construction site especially in cities are often congested and unable to provide the area required. Site accessibility Site accessibility is one of the most important factors of the implementation of IBS. IBS requires adequate site accessibility to transport IBS components from factory to the site.

b)

c)

d)

e)