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CHAPTER 1
INTRODUCTION
TO IBS
Content Summary
i.
ii.
iii.
iv.
v.
IBS benefits
vi.
vii.
viii.
ix.
Conclusion
Construction robotics
Vision 2000 by French artist Villemard in 1910
64,000 contractors
56% Bumiputra
5.0
MYR (billion)
4.3
80.0
32.7
4.1
32.3
60.0
40.0
20.0
4.7
18.3
28.2
4.4
18.2
5.4
17.2
5.6
15.7
20.3
24.3
27.1
25.2
13.1
12.3
16.1
20.9
25.0
30.5
15.5
2008
2009
2010
2011
2012
2013
2014
0.0
Residential buildings
Non-Residential buildings
34.3
27.5
Civil Engineering
29.3
Special Trade
Northern
Pop: 6.42M
19%
12%
East Coast
BioDiesel Plant at
Kuantan
Oil & Gas Industrial Park
at Pekan
Lanthanide processing
plant at Gebeng
MCKIP (Malaysia-China
Kuantan Industrial Park)
Central
Pop: 4.42M
29%
Southern
Pop: 5.47M
28%
Petronas RAPID
(Refinery and
Petrochemical Integrated
Development)
Southkey Mixed
Development
Country Garden Mixed
Development
Water Front Mixed
Development
Medini Development
6
Inconsistent quality
Manual work
Construction 69
Manufacturing 58
Introduced in 1999.
IBS Definition
Date | 16
Date | 17
18
UK
Australia
Malaysia
Author
Lu (2009)
.
19
Description
Definition
Level 0
Basic Materials
Level 1
Component sub-assembly
Level 2
Non-volumetric pre-assembly
Level 3
Volumetric pre-assembly
Level 4
Modular building
BENEFITS OF IBS
Low site workers requirement due to
simplified construction methods
Quality controlled and highly
aesthetic end products through the
process of controlled pre-fabrication
and simplified installations
Reduction of construction materials
at sites through the use of prefabricated components
Cleaner sites due to lesser
construction waste
Pre-fabrication
takes
place
at
centralized factory, thus reducing labour
requirement at site.
Reduction / elimination of
conventional timber formwork,
replaced by pre-fabricated
components and alternative
moulds with multiple usage
capability
Safer construction sites due to the
reduction of site workers, material
and construction waste
The repetitive use of system formwork
made up steel, aluminum, etc and
scaffolding provides considerable cost
savings.
Construction operation is not affected by
adverse weather condition because prefabricated component is done in a factory
controlled environment.
BENEFITS OF IBS
Date | 22
DISADVANTAGES
The size being very gigantic:
Difficulty in sending the components
but also it needs specific and large
type of formwork.
Needs large area for building the
factory, place to store the products and
movement of the lorry and so on.
DISADVANTAGES
The handling of the components needs
the involvement of heavy vehicles
such as trailers which needs a huge
amount of expenses:
It is expensive if compared to the
conventional system
Only suitable if done in a large scale,
meaning small-scale projects are not
economical
Workers issues
26
Hypothesis
IBS should look beyond product by understanding the level of industrialisation
27
Degree of industrialisation
Roger-Bruno Richard,1998
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
Low
Prefabrication
Prefabrication is a manufacturing
process that generally takes place
at a specialized facility (factory) or
onsite
Degree of Industrialisation
Roger-Bruno Richard, 1998
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
Low
Mechanisation
Degree of Industrialisation
Roger-Bruno Richard, 1998
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
Low
Automation
Mass-customization
Degree of Industrialisation
Roger-Bruno Richard, 1998
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
Low
Robotics
Construction Robotics
Construction Robotics
Construction Robotics
Degree of Industrialisation
Roger-Bruno Richard, 1998
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
Low
Reproduction
3D printing technology
Reengineering of processes
printing of component or the whole
house
3- D Printing Technology
The ink used for 3D printed houses is based on highgrade cement and glass fibre.
Basic and
fundamental
objectives of IBS
Productivity and
manpower
reduction
Reproduction reengineering of
processes and look into material to
eliminate manpower
47
Date
48|
High material
wastages
High inaccuracy,
expensive rework
Labour intensive
Hacking of bricks to
embed M&E
49
Agilia
Normal Concrete
4-5hr
4-5hr
Compressive
strength at 28days
35MPa 50MPa
25MPa 50MPa
Pumping discharge
rate
1m3/min
0.6m3/min
10MPa
10MPa
Requires troveling
Compaction
No vibration needed
Requires vibration or
external energy
Workability
High
Low
2hr
2hr
Requires vibration to
reduce air trapped
Spread/Slump
Initial setting
Achievable
compressive
strength at 12hr
Levelling
Retention period
FASTBUILD
Construction of foundation
(Reinforcement bars + concrete)
2.
3.
4.
5.
52
Watch video
4
53
The results
36% savings in cost
84% savings in time
Conventional formwork
(timber)
FastBuild
54
Conventional System
Percentage of saving
(based on 100
repetition)
Based on project at
CDL platform
Comparison on
structure only which
involved our products
Checked and verified
by chartered Quantity
Surveyor
RM 35,209.00
RM 55,746.00
36 %
1. Formwork
2. Reinforcement bars
3. Concrete
Additional works in
bricklaying and
plastering. Not material
to material comparison
include labour
Conventional System
Percentage of saving
(Based on 100
repetition)
84 %
Plastering stage
Construction completed
much earlier at Day 4
Bricklaying stage
& wall hacking to
install electrical
conduit
Construction completed at
Day 25
Conventional System
Percentage of saving
(Based on 100
repetition)
45 x 8hrs.
= 360 man-hours
244 x 8hrs.
= 1,952 man-hours
82 %
Semi-skilled for
formwork installation
& concreting in short
construction period
Brick layers,
carpenters and
plasterers in long
construction period
Saving mitigate
issue on skilled
workforces and
reducing dependency
on foreign workers
NO
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 16 16 16 14 14 14 14 14 14 14 14 16 17 18 19 20 21 22 23 24 25
1
1
1
1
1
1
1
1
1
4
2
1
1
4
2
1
4
2
1
4
2
1
4
2
1
4
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
3
2
4
9
1
9
1
9
1
9
1
9
1
9
1
7
4
3
3
3
3
1
1
1
1
1
1
2
2
2
1
1
5
5
Calculation of man-hour
244 x 8 = 1,952 man-hour
59
Plastering works
Plastering works
Plastering works
Total
Roof slab formwork preparation,
i- Civil
ii- Structural
iii- Architectural
v- Safety supervisor
Carpenter
Bar Bender
Concreter
Electrical
General Worker
Plasterer
Brick Layer
Fabrication reinforcement for Roof
Slab, Roof slab formwork preparation
Days
Striking columns formwork
1 Project Supervisor
ACTIVITY
1
1
1
1
1
1
1
1
1
4
1
4
1
4
1
4
5
7
7
7
7
Total
2
3
4
5
6
Days
Project Supervisor
i- Civil
ii- Structural
iii- Architectural
v- Safety supervisor
MFE/Carpenter
Bar Bender
Concreter
Electrical
General Worker
ACTIVITY
NO
1
8
3
1
8
4 days cycle
3
2
17
12
Calculation of man-hour
45 x 8 = 360 man-hour
In summary
61
62
References
Industrialised Building System (IBS): From prefabrication, mechanisation to
reproduction by Ir. Dr. Kamarul Anuar Mohamad Kamar, Head of Innovation
and Development , Lafarge Malaysia Berhad.