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Industrialised Building Industrialised Building System System (IBS)(IBS)

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Definition Definition

The Industrialised Building Systems (IBS) The Industrialised Building Systems (IBS) is a construction process that utilises is a construction process that utilises techniques, products, components, or techniques, products, components, or building systems which involve building systems which involve prefabricated componentsprefabricated components and onand on--site site installation. installation.

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IntroductionIntroduction

�� All building components such as wall, floor slab, All building components such as wall, floor slab, beam, column and staircases are mass produced beam, column and staircases are mass produced either in factory or at site under strict quality either in factory or at site under strict quality control and minimal on site activitiescontrol and minimal on site activities

�� Mechanisaton of the building processesMechanisaton of the building processes

�� Eg of completed building in Malaysia HUKM, Eg of completed building in Malaysia HUKM, university Hospital, Selayang Hospital, Kuala university Hospital, Selayang Hospital, Kuala Lumpur Tower< IKEA Damansara Lumpur Tower< IKEA Damansara

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Structural Category of IBS Structural Category of IBS

Based on CIDB:Based on CIDB:

Group 1Group 1: : PrePre--cast Concrete Framing, cast Concrete Framing, Panel and Box SystemsPanel and Box Systems

�� Includes precast concrete columns, Includes precast concrete columns, beams, slabs, walls beams, slabs, walls

�� 3 D components eg balconies, staircases, 3 D components eg balconies, staircases, toilets, lift chambers, refuse chamberstoilets, lift chambers, refuse chambers

�� Lightweight precast concrete and Lightweight precast concrete and permanent concrete formworkspermanent concrete formworks

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Balcony

Beams

Group 1Group 1

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PrePre-- cast cast Concrete Concrete

ComponentsComponents

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Group 2Group 2:: Steel Formwork SystemsSteel Formwork Systems

�� eg tunnel forms, tilteg tunnel forms, tilt--up systemup system

�� beams/columns moulding and beams/columns moulding and

�� permanent formworkspermanent formworks

Structural Category of IBS Structural Category of IBS

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Group 2Group 2

Tilt-up system

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Group 3Group 3:: Steel Framing SystemsSteel Framing Systems

�� Steel framing system eg steel trusses, Steel framing system eg steel trusses, columns, beams and portal frame systemcolumns, beams and portal frame system

Structural Category of IBS Structural Category of IBS

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Group 4:Group 4: Prefabricated Timber Prefabricated Timber Framing SystemsFraming Systems

�� Prefabricated timber framing systems Prefabricated timber framing systems consists of prefabricated timber consists of prefabricated timber trusses, beams and columnstrusses, beams and columns

Structural Category of IBS Structural Category of IBS

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Group 5Group 5:: Block Work SystemsBlock Work Systems

�� Blockwork system includes interlocking Blockwork system includes interlocking concrete masonry unit (CMU)concrete masonry unit (CMU)

�� Lightweight concrete blocksLightweight concrete blocks

Structural Category of IBS Structural Category of IBS

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PrePre--cast Concretecast Concrete

�� Concrete cast into Concrete cast into desired shapes prior desired shapes prior to placement in a to placement in a structurestructure

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PrePre--cast Concretecast Concrete

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Prestressed ConcretePrestressed Concrete

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ErectionErection

� The assembly of parts put together in different ways to form the total building fabric

� The parts meet at joints or connections

� Joint refers to the space between components whether or not they are in contact

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Frame JointsFrame Joints

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Precast Frame JointsPrecast Frame Joints

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Advantages of PreAdvantages of Pre--cast concrete cast concrete system (1)system (1)

�� High level mechanisation thus precisionHigh level mechanisation thus precision

�� No delay due to bad weather and manpowerNo delay due to bad weather and manpower

�� Application of modular design in standardising Application of modular design in standardising dimensions dimensions

�� Work done concurrently at factory and at site Work done concurrently at factory and at site thus speed up constructionthus speed up construction

� Low site workers requirement due to simplified construction methods

� Quality controlled and highly aesthetic end products

� Reduction of construction materials at sites

�� Save costsSave costs

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� Reduction / elimination of conventional timber formworks

� Reduction / elimination of props

� Reduction of construction wastes

� Cleaner sites

� safer construction sites

� Faster completion of construction projects

� Cheaper total construction costs made possible due to all of the above

Advantages of PreAdvantages of Pre--cast concrete cast concrete system (2)system (2)

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�� Is a concept of coordination of dimensions Is a concept of coordination of dimensions and space in which building and and space in which building and components are dimensioned and components are dimensioned and positioned in terms of basic units or positioned in terms of basic units or modules known as 1M = 100mm modules known as 1M = 100mm

�� MS 1064: 2001 MS 1064: 2001 –– Malaysian Standard for Malaysian Standard for modular coordinationmodular coordination

Modular Coordination (MC)Modular Coordination (MC)

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Why MCWhy MC

�� Provide a coherent method for Provide a coherent method for coordinatingcoordinating the the position and dimension of components in the position and dimension of components in the planning and designplanning and design of buildingsof buildings

�� Improve productivity in building industry. Improve productivity in building industry. MC MC facilitate achievement of industrilisationfacilitate achievement of industrilisation

�� Provide Provide guide to component sizesguide to component sizes thus thus reduce reduce work on sitework on site eg trimming and shaping hence eg trimming and shaping hence reduce wastage and labourreduce wastage and labour

�� Standardisation Standardisation simplify site operationsimplify site operation by by rationalising setting out, positioning and rationalising setting out, positioning and assembly of building componentsassembly of building components

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Examples: IBSExamples: IBS

�� The construction of Police Station in The construction of Police Station in Senawang Negeri Sembilan:Senawang Negeri Sembilan:

Comprises of 1 unit of Police Station Office Comprises of 1 unit of Police Station Office Block, 4 units of Class F Quarters and 2 Block, 4 units of Class F Quarters and 2 Units of Class G Quarters and the External Units of Class G Quarters and the External worksworks

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THE CONSTRUCTION OF QUARTERS GTHE CONSTRUCTION OF QUARTERS G

�� The Block comprises of 5 Storey Building The Block comprises of 5 Storey Building as shown in the picture as shown in the picture

QUARTERS GQUARTERS G

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Precast WallPrecast Wall Precast SlabPrecast Slab

LevelLevel Block Block G1G1

Block Block G2G2

Block Block G1G1

Block G2Block G2

11 9191 9191 00 00

22 9494 9494 102102 102102

33 9494 9494 102102 102102

44 9494 9494 102102 102102

Upper Upper RoofRoof

11 11 00 00

468468 468468 408408 408408

NUMBERS OF PANELS USEDNUMBERS OF PANELS USED

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CONSTRUCTION PROCESS USING PRECAST PANELS

PILING

PILE CAP

STUMP

GROUND BEAM

FLOOR SLAB

COLUMN

INSTALLATION OF CONCRETE WALL PANEL

INSTALLATION OF FLOOR SLAB CONCRETE PANEL

CONCRETE TOPPING ON FLOOR SLAB

PROCESS REPEATED FOR SUCCESIVE FLOOR

cast insitu

cast insitu

cast insitu

cast insitu

precast

precast

cast insitu26

PILING WORK FOR FOUNDATION

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PREPARATION OF PILE CAP (CAST INSITU)

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PREPARATION OF COLUMN STUMP (CAST INSITU)

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INSTALLATION OF ‘300 MM x 25 MM DIA.- DOWEL BAR’ AT GROUND BEAM

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CONSTRUCTION OF GROUND BEAM (CAST INSITU)

DowelBar

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‘MOULD’ FOR THE PRECAST CONCRETE PANEL WAS FABRICATED IN THE FACTORY ACCORDING TO THE DESIGN SPECIFICATIONS INCLUDING REQUIREMENTS FOR ELECTRICAL INSTALLATION

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‘MOULD’ FOR THE PRECAST CONCRETE PANEL

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CASTING PROCESS IN A FACTORY

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WORK ON CASTING IN PROGRESS IN A FACTORY

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COMPLETED WALL PANELS

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PANELS TO BE TRANSPORTED TO CONSTRUCTION SITES

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THE USE OF FULL TIME CRANE FOR THE HOISTING AND INSTALLATION OF PANELS

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CAST IN SITU COLUMNS READY FOR PANEL INSTALLATION

COLUMNS ARE READY FOR THE INSTALLATION OF SUCCESSIVE PANELS

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ONE CRANE AND 5 SKILLED WORKERS WERE USED FOR THE INSTALLATION OF THE PRECAST CONCRETE PANELS

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WORKS ON INSTALLATION OF WALL PANELS USING A CRANE

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DOWEL BARS WERE SLOT TO THE HOLE SLOT UNDERNEATH THE PANEL FOR CONNECTION

Installation of Precast Panels

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PANELS WERE HOIST THROUGH PROPER HOOKS AND FIXED PANELS WERE HOIST THROUGH PROPER HOOKS AND FIXED

THROUGH THE PANEL CONNECTION SLOTSTHROUGH THE PANEL CONNECTION SLOTS48

TEMPORARY SUPPORT WRE USED IN WALL INSTALLATION FOR

VERTICAL ALIGNMENT

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THE USE OF PANEL-SUPPORT IS TO ENSURE THE VERTICALITY IN POSITIONING OF PANELS

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CONCRETE JOINTS BETWEEN COLUMN AND WALL PANELS

CONCRETING OF THE JOINTS USING CONCRETE CHIPPING OF

GRADE 25

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CROSS-SECTION OF PANEL JOINT DETAIL

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GROUTING OF THE JOINTS BETWEEN WALL AND COLUMNGROUTING OF THE JOINTS BETWEEN WALL AND COLUMN

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COMPLETED COLUMN/PANEL JOINT

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GROUTING IN PROGRESS USING GROUTING MATERIAL‘EMCRETE S’

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INSTALLATION OF PRECAST FLOOR SLAB PANEL

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FLOOR SLAB PANELS FIXED TO POSITION

BOTTOM VIEW58

ELECTRICAL CONDUITS AND RETICULATION PIPES ARE INSTALLED AND FIXED INTO POSITION BEFORE CONCRETE TOPPING WERE CARRIED OUT

PREPARATION OF FLOOR SLAB CONCRETE TOPPING

(CAST INSITU)

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COMPLETED FLOOR SLAB

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ROOF TRUSS OF QUARTERS G

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FINISHING AND FINAL TOUCH- UP

PAINTINGS

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QUARTERS G NEARLY COMPLETION

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INTERNAL VIEW OF QUARTERS G

DINING

KITCHEN

LOUNGE

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OTHER EXAMPLE OF PRECAST OTHER EXAMPLE OF PRECAST CONCRETE PANELS CONSTRUCTIONCONCRETE PANELS CONSTRUCTION

�� Construction of Quarters in Audit Academy Construction of Quarters in Audit Academy in Negeri Sembilanin Negeri Sembilan

�� More Types of Precast Panels were used More Types of Precast Panels were used in the constructionin the construction

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Hollow Core SlabHollow Core SlabHollow Core SlabHollow Core SlabHollow Core SlabHollow Core SlabHollow Core SlabHollow Core Slab 1927.0 m1927.0 m1927.0 m1927.0 m1927.0 m1927.0 m1927.0 m1927.0 m22222222

Precast PlankPrecast PlankPrecast PlankPrecast PlankPrecast PlankPrecast PlankPrecast PlankPrecast Plank 291.0 m291.0 m291.0 m291.0 m291.0 m291.0 m291.0 m291.0 m22222222

Precast BalconyPrecast BalconyPrecast BalconyPrecast BalconyPrecast BalconyPrecast BalconyPrecast BalconyPrecast Balcony 16 nos.16 nos.16 nos.16 nos.16 nos.16 nos.16 nos.16 nos.

Precast BeamPrecast BeamPrecast BeamPrecast BeamPrecast BeamPrecast BeamPrecast BeamPrecast Beam 136 nos.136 nos.136 nos.136 nos.136 nos.136 nos.136 nos.136 nos.

Precast ColumnPrecast ColumnPrecast ColumnPrecast ColumnPrecast ColumnPrecast ColumnPrecast ColumnPrecast Column 63 nos.63 nos.63 nos.63 nos.63 nos.63 nos.63 nos.63 nos.

Precast StaircasePrecast StaircasePrecast StaircasePrecast StaircasePrecast StaircasePrecast StaircasePrecast StaircasePrecast Staircase

(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)(Flight & Landing Elements)

12 nos.12 nos.12 nos.12 nos.12 nos.12 nos.12 nos.12 nos.

Precast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing WallsPrecast Parapet & Load Bearing Walls 200 nos.200 nos.200 nos.200 nos.200 nos.200 nos.200 nos.200 nos.

Components delivered for this projectComponents delivered for this projectComponents delivered for this projectComponents delivered for this projectComponents delivered for this projectComponents delivered for this projectComponents delivered for this projectComponents delivered for this project

are as below:are as below:are as below:are as below:are as below:are as below:are as below:are as below:

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SOME COMPLETED PROJECT PHOTOS USING SOME COMPLETED PROJECT PHOTOS USING PRECAST CONCRETE STRUCTUREPRECAST CONCRETE STRUCTURE

--Commercial Building CategoryCommercial Building Category

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SOME COMPLETED PROJECT PHOTOS USING PRECAST SOME COMPLETED PROJECT PHOTOS USING PRECAST

CONCRETE STRUCTURECONCRETE STRUCTURE

--Public Building CategoryPublic Building Category

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