DCC2052 INTRODUCTION TO

INDUSTRIALISED BUILDING
SYSTEM (IBS)

UNIT 1:

INTRODUCTION

PREPARED BY : CABM
 SUMMARY OF THE TOPIC
• This topic covers the basic knowledge of Industrialised Building
System (IBS) including the definition, sustainable construction,
overview and evolution. Also includes the types of precast panel,
advantages, disadvantages, future, forecast the demand for
Industrialised Building System (IBS).
• Know the basic concept of Industrialised Building System (IBS)
• Understand the advantages and disadvantage of IBS
• Apply the needs of IBS
 Definition IBS

IBS – Industrialised Building System @ Sistem Binaan

Berindustri
As a construction method where the component are
manufactured (factory or site), transported and installed
at site with minimum site workers
 Manufacture

Transport

Installation
 Comparison

Conventional method IBS method

0 % IBS 100 % IBS

 Site Comparison

Conventional method IBS method

 Comparison
PRECAST GROUND BEAM

Conventional method IBS method

 Comparison IBS with Conventional Construction Method
IBS
Higher quality products with minimum wastages
due factory-controlled prefabrication environment
Elimination of the timber formwork usage and
great reduction of props through the usage of
prefabricated element or system formwork for site
casting
Faster completion due to the introduction of
prefabricated components replacing in-situ
construction
Sturdy and safe work platform provided by the
prefabricated elements
Minimum labour usage as bricklaying and
plastering work is no longer used
Less cost, effective time and better in overall
construction management due to all the above
Conventional
Less quality product with more
wastage
75% of the construction goes to the
formwork cost
Construction work also takes a long
time to complete
Unsafe and messy work platform
Cost of labour increase
A lot of problem in construction
management due to inefficiency time
to finish and cost of overall
construction
 trusses
column beam

staircase Building floor

WHAT IS SUSTAINABLE CONSTRUCTION???
IBS contribute to Sustainable and Green Construction in the Future:

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.
 Easier to control the workmanship, ensuring a tighter construction,
reducing energy losses due to leakage (i.e. thermal leakage)
IBS and Waste
 IBS traditionally has been know to minimize waste
 Ability to reuse materials from one module or product into another, the
sustainability agenda is supported through its usage.
 Materials and production management have to be monitored in order to
achieve waste minimization.
IBS and logistics
 The amount of environmental impact from material transportation
activities to be one third of total environmental impact on the entire
construction process.
 IBS offer another benefit, which is the ability to order in large quantity.
 Thus reducing the number to trips to be taken.
IBS and economic sustainability
 Government emphasize on reduction of reliance on foreign labours.
 Low outflow of ringgit, generate national income
 There is the need to develop detailed training and preparing the
workforce for wide scale executions.
 Roadmap IBS 2003-2010 telah
diluluskan oleh Menteri Kabinet
pada 29 October 2003
 Ke arah memodenkan industri
pembinaan Negara dan memacu
Konsep Pembinaan Terbuka
sebagai matlamat jangka panjang
 Peningkatan kualiti, produktiviti,
keselamatan, menyeragamkan
rekabentuk dan daya saing di
dalam industri pembinaan.
 Pengurangan pergantungan
kepada tenaga kerja asing ke tahap
15% pada 2010
ROADMAP 2011-2015
ROADMAP 2011-2015
 LATEST

CITP – Construction Industry Transformation Program

1: SISTEM KONKRIT PRA-TUANG / PRECAST CONCRETE

PC columns, beams,

2 slabs, 3D-components
(balconies, staircases,
toilets, lift chambers, box
girders, etc)
Factory-made
Site-Casting
2: MOULD SYSTEM

Tunnel forms, beams

and column moulding

2
forms, permanent steel
formworks (metal decks),
etc.
 Acuan Besi keluli

Acuan Aluminium
Acuan Bateri
3 : STEEL FRAME

Steel beams and

columns, portal
frames,roof trusses, etc
4: PRE-FABRICATED TIMBER

Timber frames,
pre-fab timber

2
roof trusses, etc.

31
5 : BLOCK

Interlocking concrete
masonry unit (CMU),

2 lightweight concrete blocks,

etc.
IBS BLOCK
6 : OTHER INNOVATION SYSTEM

35
BOX SYSTEM
Parcel 5 & 6, Precinct 9 Parcel 4, Precinct 9
750 units (900 sqft) 520 units (1000 sqft)
Durations : 18 months Durations : 18 months
 
Name of Custom, Immigration & Quarantine
Building Complex, Johor Bahru

Location Johor Bahru

Precast concrete beams, columns and

IBS System
hollow core slabs

Owner Public Works Department, Malaysia.

 
Apartment for Government Staff,
Name of Building
Putrajaya

Location Parcel 8, Precinct 9, Putrajaya

IBS System Precast concrete walls

Owner Putrajaya Holding Sdn. Bhd.

 

Name of Building Telekom Tower, Kuala Lumpur

Location Jalan Pantai Baru, Kuala Lumpur.

Steel structure for the sky garden

IBS System
and top part of the building

Owner Telekom Malaysia Bhd.

Name of Building Water Sports Complex, Putrajaya

Location Precinct 6 Promenade, Putrajaya.

Tubular steel, steel decking for the

IBS System
floor system

Owner Perbadanan Putrajaya.

 
Name of Kuala Lumpur International Airport
Building (KLIA), Sepang

Location Sepang, Selangor.

IBS System Steel roof structure

Owner Malaysia Airport Berhad.

 

Name of Building KL Sentral Station, Kuala Lumpur 

Location Brickfields, Kuala Lumpur

Steel roof structure, precast hollow

IBS System
core slabs.

Owner Kuala Lumpur Sentral Sdn. Bhd.

40
a)Reduction of site labour
b)Minimal Wastage
c)Less site material
d)Cleaner environment
e)Controlled quality
f)Neater and safer sites
g)Faster project completion
h)Lower total construction costs due to the above
1) Speedy Construction - Lesser time to:
• Faster completion of projects due to advance off-site preparations
and efficient installations.
• Manageable construction schedule by the use of planning control,
estimated lead time and forecasted down time.
• Not affected by weather element as off-site production allows 24-
hours operation.
• Fabricate
• Erect & Dismantle formwork
• Curing (concrete)
2) Saving in Labour
Higher degree of mechanization
Reduced unskilled & skilled labour
Increased usage of plant machinery; tower cranes & mobile loaders
3) Optimising Material Use
Higher Degree of Precision
Accuracy in Production & Assembly Processes
Reduce Material Waste
4) Better Quality- Factory Produced
•Consistent high quality-controlled products through practice of
Standard Operating Procedure (SOP).
•Eliminate substandard product through ‘zero-defect’ programme.
•Skilled workers with specific scope of works improve efficiencies
and reduce errors - Minimises Errors & Imperfection - Better
workmanship
•Superior Finishes
5) Less Prone to Weather Changes
Work (most) done in Factory Environment
Production Unaffected by Weather
6) Cost Effective
•Requirement of few on-site workers significantly reducing labour cost
for contractors (installers).
•Minimum material waste through quality control and continuous
improvement.
•Sustainability as component moulds could be used repeatedly for
different projects, allowing economic of scale and reduction in
amortization cost.
•Exemption of the Construction Levy on residential developments with
at least 50% of IBS content
•Off-Set High initial Cost by Large Projects (Usually)
•Faster turnover
•Savings on overheads & other Operational Costs
7) Safety
•Promote safe and systematic factory working environment.
•Safer working environment as minimal work is required on-site.
•Cleaner sites due to timely material delivery, systematic components
storage, reduction of construction material and waste on-site
DISADVANTAGES OF IBS
1) High Initial Capital Cost
Constructing Factory
Casting Beds (Due to new production)
Support Machinery/Plants
Only 15% contractors using IBS, because
the low labour cost in this country is the
root causes.
Labour cost is cheap, so why IBS?
2) Sophisticated Plants & Skilled Operators
High Maintenance of Plants
Require Coordination by skilled operators
Dependence on the smooth running of all sections
•Lack of experience practicing/designing IBS by the
consultants/contractors/clients
•Short of experience workers in the manufacturing and installation
works (most of them are foreign workers)
•Defect works by previous pre cast system (close system)
•QS lack of experience pricing the IBS projects (most of them not
pricing the total cost of project)
3) Lacking in Water Tightness
Water leakage quoted as Major Problem esp in Malaysia
4) Site Accessibility-Require good road network
Transportation of heavy IBS to Site
5) Require Large Work Area
Factory
Tower-cranes
Trailers
Storage Space for IBS
Most Construction sites are
Congested
6)
Monopoly of Fabricators
Conventional builders denied of Profit Margin
Fabricators dictate Construction Design & Processes
CHALLENGER FOR INDUSTRY PLAYER

Designer i. Not popular choice among designer as limiting

creativity in design
ii. Lack of IBS design knowledge
iii. Proprietary system make it hard to be adopted
by designer
Contractor i. Current exemption from levy can’t cover
additional cost
ii. Insufficient push factor from the end buyer
for IBS properties
Manufacturer i. Lack of quality control in smaller IBS
manufacturer
ii. Lack of local R&D, support services,
technologies and testing lab
iii. Lack of innovative product that can enhance
aesthetic values of buildability.
 THANK YOU…
ANY QUESTION