Industralised Building

System
BY DR LEE YEE YONG
Terminology used in the Method of
Construction Industry

Source: Mohamed Nor

Azhari Azman et al., 2011
IBS
IBS
 Definition IBS
IBS as process by which components of building are conceived, planned and
fabricated at factory, transported, and erected at site. The system combined
software and hardware, including system design, which is complex process of
studying the requirement of end user, market analysis and the development of
standardize component.
Junid (1986)

IBS as a system which use industrialised production technique either in the

production of component or assembly of the building or both.
Parid (1997)
 Definition IBS
IBS as a construction system that is built using pre-fabricating components. The
manufacturing of the components is systematically done using machine, formworks and
other forms of equipment. The components are manufactured offsite and once
completed will be delivered to construction sites for assembly and erection.
Rahman and Omar (2006)

IBS as a mass production of building components either in factory or at site according to

the specification with standard shape and dimensions and transport to the construction
site to be re-arranged with certain standard to form a building.
Chung and kadir (2007)
 Definition IBS
IBS as a construction process that utilizes techniques, products, components, or
building systems which involved prefabrication works (off-site of on-site) under
controlled environment, transported, positioned and on-site installation with minimum
site works.
IBS Roadmap (2003)
 Characteristic of IBS
i. Closed system
o Is a system where all elements of industrial production of components to be used for specific designs
for specific projects. The system does not allow for the interchangeability of components from different
factories.
oproduction based on client’s design
oproduction based on precaster’s design

o 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.
o The architectural design observes large repetitive element and standardisation.
o There is a sufficient demand for a typical type of building such as school so that a mass production can be
obtained.
o There is an intensive marketing strategy by precaster to enlighten the clients and designer the potential benefit
of the system in term of economics and noneconomic aspects.
Characteristic of IBS
ii. Open System
o allow the precaster to produce a limited number of elements with a predetermined range of
product and at the same time maintaining architectural aesthetic value.
o Is a system which allows the production of building components by various factories and to
be compatible with each other to be used in any building project.

iii. Modular Coordination

o Modular co-ordination is a co-ordinated unified system for dimensioning spaces,
components, fitting, etc. so that all elements fit together without cutting or
extending even when the components and fittings are manufactured by different
suppliers.
oIs an international system of dimensional standardisation in building where buildings
and components are sized in term of a basic unit or module
 Characteristic of IBS
iv. Standardisation and Tolerances
o 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 (Trikha,
1999).
v. Mass Production
o The investment in equipment, human recourses, and facilities associated with an industrialisation
can be justified economically only when large production volume is observed.
vi. Specialisation
o 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 (Warszawski, 1999).
 Characteristic of IBS
vii. Good Organisation
o High production volume, specialisation of work, and centralisation of production requires a
efficient and experiences organisation capable of a high level of planning, organising,
coordination and control function with respect to production and distribution of the
products (Warszawski, 1999).
viii. Integration
o 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.
ix. Production Facility
o The initial capital investment for setting up a permanent factor is relatively experience. On
the other hand, a temporary casting yard or factory can be established at the project site in
order to minimise the transportation costs (Peng, 1986).
 Characteristic of IBS
x. Transportation
o It is found that casting of large-panel system can reduce labour cost up to 30
percent. However, these cost savings are partially offset by the transportation costs.
The transportation of large panels is also subject to the country’s road department
requirement. These limitations must be taken into consideration when adopting a
prefabrication system (Peng, 1986).
xi. Equipment at Site
o For the purpose of erecting and assembling precast panels into their position,
heavy crane is required especially for multi-storey building.
 Characteristic of IBS
Another 5 characteristic of IBS are:
a) Industrial production of components through prefabrication. OR
sometime highly mechanized in situ process i.e. permanent steel
formworks, tunnel forms, etc.
b) Reduce labour during prefabrication of components and site workers
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 application, and
adaptable to standardization and modular coordination.
Types of IBS
Based on structural aspects, IBS can be divided into five major types:
Type 1: pre-cast concrete framing, panel
and box system.
• Precast concrete columns, beams, slabs, walls, “3-D” components, permanent concrete
formworks, etc.
Type 1: pre-cast concrete framing, panel
and box system.
• Precast concrete columns, beams, slabs, walls, “3-D” components, permanent concrete
formworks, etc.

Precast concrete framing

Type 1: pre-cast concrete framing, panel
and box system.
• In the evaluation of the systems, various parameters such as the industrialized
process used, the transportation and erection problems, architectural features
and the sosio-economic problems must be considered.

Frame system
•Frame structures may be defined as those structures that carry the loads
through their beams and girders to column and to the ground
•Their important feature is the capacity to transfer heavy loads over large spans.
•Used in the construction of bridges, parking lots, warehouses and so on.
Type 1: pre-cast concrete framing, panel
and box system.
• Precast concrete columns, beams, slabs, walls, “3-D” components, permanent concrete
formworks, etc.

Precast concrete – panel system

 Type 1: pre-cast concrete framing, panel
and box system.
Panel system
•Panel system may be defined as those structures that carry
the load through large floor and wall panels.
•Concrete panel systems are extensively used in Europe for
high rise building for ease of construction purpose.
•Used in Hollow core slabs, interior & Exterior wall.
Type 1: pre-cast concrete framing, panel
and box system.
• Precast concrete columns, beams, slabs, walls, “3-D” components, permanent concrete
formworks, etc.

Precast concrete – box system

 Type 1: pre-cast concrete framing, panel
and box system.
Box system
Box system may be defined as those systems that use 3D
modules (or boxes) for fabrication of habitat units.
The main features of this system are in the internal stability
as it can withstand load from various directions.
Required only large prefabricated sections to be
transported or handled at one time.
Type 2 – Steel Formwork system
• includes tunnel forms, tillt-up systems, beams and column moulding forms and permanent steel
formworks.
Type 3 – Steel Framing system
• steel beams and columns, portal frame systems, roof trusses, etc
Type 4 – Prefabricated Timber Framing
System
• Prefabricated timber trusses, beam and columns, roof trusses.
Type 5 – Block work system
• interlocking concrete masonry units and lightweight concrete
blocks
Type 6 - Hybrid/Innovative System (1+2+5)
•This is the latest IBS type which incorporates various “green” elements.
•An example of the innovation is the mixture of two elements such as
polystyrene and concrete, to produce IBS components for use in the
construction of a wall which has better heat insulation properties.
•With the advancement in technology and innovation, new materials are
being introduced at the fabrication stage.
•Some of the new materials introduced in IBS include gypsum, wood wool,
polymer, fiberglass and aluminium-based IBS components.
Why we need IBS system?
Scenario in Construction Industry
Compared to other sectors, the construction industry suffers from
low productivity, safety and quality control. Due to the traditional
labor-intensive practices, the 3-D Syndrome (Dirty, Difficult &
Dangerous) has always been associated with the construction
industry.
 ISSUES PERTAINING TO CONSTRUCTION
COSTS
Time Delay
 problems of financing, non-payment for completed works, poor contract management, changes in site
conditions, shortage of materials, design changes and weather conditions
 Time delay a major reason of escalating project costs

Labor costs
 Too much reliance on foreign workers

Wastage costs
 Waste has direct impact on the productivity, material loss and completion time of project resulting in loss
of a significant amount of revenue
 Earthworks arising from excavation of land; Off-cuts, excess and broken materials arising from new
construction works; Materials, arising from the repair and maintenance of building, roads and waterways;
Materials arising from the rehabilitation of housing or reconstruction of non-residential buildings.
 Illegal dumping of waste material.
Advantages of IBS system
i. Less construction time
ii. Cost saving
iii. Saving in labours
iv. Less labour at site
v. Optimized use of materials
vi. Higher/control quality and
better finishes
vii. Construction operation
less affected by weather
viii.Flexibility
ix. Increase site safety and
neatness
x. Environmental friendly
xi. Minimal wastage
Benefits of IBS system
i. Facilitates cooperation between designer, manufacturer,
distributor, contractor & authorities.
ii. Dimensioned: standard components without restriction
on freedom of design.
iii. Optimizes the number of standard sizes of building
components.
Benefits of IBS system
iv. Permits a flexible types of standardization.
v. Encourage interchangeability of components
(material, forms or methods of manufacturer).
vi. Simplified the site operation.
vii.Ensures dimensional coordination between
installation.
IBS method can be green. IBS should be promoted as a
greener construction practice based on

(i)speedier completion;
(ii) lower on-site wastes; and
(iii) lower cost
IBS adoption still low
According to a survey by the Construction Industry
Development Board (CIDB), private sector adoption is still
low at around 15%, while government projects are seeing
higher adoption at 70%
(Ahmad Naqib Idris – The edge Financial Daily, 2017)
Problems and challenges
i. Lack of Expertise / Lack of knowledge
ii. Limited Enforcement of Industrialised
Building Systems (IBS) Requirements
iii.Cost
Lack of Expertise / Lack of knowledge
Lack of experience practicing/designing IBS by the
consultants/contractors/clients
Short of experience workers in the manufacturing and installation
works (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)
Limited Enforcement of Industrialised
Building Systems (IBS) Requirements
Despite of massive government’s initiatives to increase the
utilization of IBS for every construction projects in Malaysia, the
execution process was believed not strongly enforced.
This particular initiative could only be realized if one of the
strategies to IBS adoption is to include the IBS score as part of
satisfactory conditions before the granting of development
orders by local authorities
Incentive and regulatory requirements for the introduction
and adoption of IBS should be the next plan of action to be
headed by CIDB
Cost
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
Low labour cost using foreign unskilled general workers
(labour cost is cheap).
 Challenges (others)
Construction sector is known to be a traditional sector that can be
characterised as reluctant and resistant to change.
Application of payments - IBS manufacturers will impose an initial
payment or deposit to contractors for the purchase and delivery of IBS
components
High investment cost
Break even on point - inconsistency in business volume and lack of
business continuity over time may also result in the investment of the
latest innovation not being commercially sustainable
 Challenges (others)
The weak level of integration - Poor communication and poor coordination
among project team members may also contribute to the problem -
contributing to “constructibility” issues during the installation process on site.
Design processes based on conventional practice
Shortage of skilled workers and limited training
Lack of standardisation in designs - there has not been any standardisation
codes in IBS project design works done by consultants; inconsistency in design
which complicates the installation by the contractor at the construction site
 No. Name of Project Year
1. Pekeliling Flat, Kuala Lumpur 1966
2. The Rifle Range Flat, Penang 1966
3. Petronas Twin Towers 1999
4. Bukit Jalil Sports Complex and Games Village 1996
5. Kuala Lumpur International Airport (KLIA) 1993
6. SJKC Damansara Petaling Jaya, Selangor Darul Ehsan 2001
7. SK Brickfields 1, Kuala Lumpur 2003

List of IBS 8.
9.
Projek Akademi Audit Negara, Nilai Negeri Sembilan
Dewan Milenium, Kepala Batas, Pulau Pinang
2005
2014

projects in 10. Northam City, Pulau Pinang -

Malaysia 11. Teachers Quarters, all over Malaysia -

12. Akademi Binaan Malaysia, Sintok, Kedah 2007
13. IKEA Mutiara Damansara, Selangor 2004
14. Apartments, Precint 9, Wilayah Perseketuan Putrajaya 2014
15. Private Residential House, Kampung Gita, Sarawak 2014
16. Surau Kampung Kudei, Kuching 2012
17. Administration Block,Hostel Block and Faculty Block 2005
 HILLCREST HEIGHTS @ PUCHONG, Kimlun berhad

Custom, Immigration & Quarantine Complex, Johor

Bahru Precast concrete beams, columns and hollow core
slabs
 Kuala Lumpur International Airport (KLIA), Sepang
- Steel roof structure

Platinum park,
phase 3, KL
(NAZA tower & Serdang Hospital - Steel beams and columns,
Tabung Haji precast concrete half slabs
tower) – steel
formwork
system
 No. Name of Projects Year

1. 5 units of JKR Standard Mini Libraries in Kuching 2007

areas
2. SCIB Precast Factory Extension 2007

3. The Spring Shopping Mall, Kuching 2007

4. Private Residential House, Kampung Gita 2008

List of IBS 5.

6.
Surau Kampung Kudei, Kuching 2012

Administration Block, Institute of Aminuddin Baki, 2005

projects in 7.
Kuching
Hostel Block, Institute of Aminudin Baki, Kuching 2005
Sarawak 8. Faculty Block, Institute of Aminuddin Baki, Kuching 2005

9. Faculty of Medicine and Health Sciences of University 2006

Malaysia Sarawak (UNIMAS)

10. Extension of Kuching International Airport (KIA) 2006

 Private Residential House, Kampung Gita Surau Kampung Kudei, Kuching

Faculty Block, Institute of Aminuddin Baki, Kuching Extension of Kuching International Airport (KIA)
DISADVANTAGES OF IBS
High initial capital cost
Problem of joints
Sophisticated plants and skilled operators
Site accessibility
Large working area