Concrete Plant International Vol.

5, pp36-38

Mohamad Zain Hashim was a Civil Engineer for more than 10 years before
joining as a lecturer at the Faculty of Civil Engineering, Universiti Teknologi
MARA (UiTM), Penang. He obtained his first degree in Civil Engineering from
Universiti Teknologi Malaysia (UTM) and pursued his Master at Universiti
Sains Malaysia (USM). His research interests include construction
management, structural analysis and slope study.
mzain.hashim@ppinang.uitm.edu.my

Mohamed Nor Azhari Azman is a lecturer at the Faculty of Technical and

Vocational, Sultan Idris University of Education. He received a Bachelor’s
of Engineering in Civil Engineering degree from Universiti Teknologi
Petronas (UTP) in 2004 with Honors. He also hold a Master in GIS from
Universiti Sains Malaysia. Research interests focus on the study of
Industrialised Building System (IBS), precast manufacturing plant and
spatial site selection. mnazhari@upsi.edu.my

Mohd Sanusi S. Ahamad is an Associate Professor at the School of Civil

Engineering, Universiti Sains Malaysia. He holds a Master and Doctoral
Degree in GIS from University of Nottingham, United Kingdom. His
research interest is in spatial site selection and spatial decision process.
cesanusi@eng.usm.my
Concrete Plant International Vol. 5, pp36-38

CONSTRUCTABILITY OF IBS BLOCKWORK SYSTEM FOR BUNGALOW HOUSE

Abstract

The Malaysia construction industry faces unique challenges in transforming construction into
a modern and efficient industry by using Industrialised Building System (IBS). It involves
prefabrication and installation of components at the construction site. Currently the most
popular type of manufacturing in Malaysia is off-site which is situated at a significant distance
from the site. Modern methods of construction (MMC) is the term used by the UK government
to describe a number of innovations in house building, most of which are offsite technologies,
moving work from the construction site to the factory. The current system of IBS consists of
precast component systems, formworks systems, steel framing systems, prefabricated timber
framing systems, block work systems and innovative systems, which have started to replace
the wet construction (traditional method). This research studies is to highlight the benefits of
block work systems in the Malaysian construction industry which contributes to the fast track
of project, affordability of business, improve the quality and long lasting of products.
1 1
Mohamad Zain Hashim , Faculty of Civil Engineering, UniversitiTeknologi MARA, Penang, Malaysia
†2
Mohamed Nor Azhari Azman , School of Civil Engineering, Universiti Sains Malaysia, 14300 Nibong
2
Tebal, Penang
3
Mohd Sanusi S. Ahamad , School of Civil Engineering, Universiti Sains Malaysia, 14300 Nibong
2
Tebal, Penang
4 3
Awi Shahadan , Binaan Desjaya Sdn Bhd, Bandar Indera Mahkota, 25200 Kuantan, Pahang

INTRODUCTION

Industrialized building system (IBS) is defined as a construction system where components are
manufactured at factories on or off-site, transported and then assembled into a structure with minimum
work. In addition, the traditional construction industry in United Kingdom that consist of cast-in-situ
concrete and structural steelwork have transformed into mixed construction which consist of precast
concrete with steelwork, timber, cast-in-situ concrete and masonry (Elliott, 2002). Notwithstanding, IBS
technology should not be seen as a threat to traditional methods, but both methods should be able to
work in tandem and improve their processes collectively. The sharing of best practice between the two
approaches is essential for the continued successful development of both construction sectors.
Technology and global standardization has changed the past practice of construction. This has
affected the land resources, social environment and local skills to cater the demand for various types
of homes. In order to meet this demand the local authority must have detail knowledge of the needs of
the lower income group to build affordable homes. The first shelters and settlements were
constructed from stone, mud and materials collected from the forest; which acts as protection against
the cold, wind and rain. The method used to construct these shelters grew out of countless
experiments and the experience gained from the trial and error was passed from generation to
generation who continued to use the successful construction method. Most of the construction in the
early communities is to accelerate the constructions’ development and to ensure the increase in
productivity through importation of the construction technology from overseas. Not all of the advanced
construction technology could be adopted to suit the local condition which needs to be adjusted to
factors such as the environment, level of workers skills and knowledge competence, availability of
resources and manufacturers to fabricate mass production and high-quality product.
Constructing a building or a house using a conventional method will usually take a long period of
time and require a lot of manpower. However, with the introduction of Industrialised Building System
(IBS) the daunting work of construction can be expedited and completed within a shorter period of
time, involving minimal manpower. What is IBS? IBS is a system in which the construction materials
such as wall, beam slab, etc are manufactured in a large quantity at a factory or a specific site instead
of at the construction site itself. These materials are then transported to the construction site and
ready for installation (Trikha and Ali, 2004).
In Malaysia, IBS was introduced in mid 1960’s. In the beginning, many construction companies
were not interested to adopt the new system. However, at present the system is widely used in
Malaysian construction industry due to its quality, efficiency, competency and sustainability. This is
proven by the growing number of IBS manufacturers, from only 21 IBS manufactures in 2002 to 143
factories in 2009 (Azman et al., 2010b). In promoting the further development of research and among
the leading manufacturer of IBS is Binaan Desjaya Sdn Bhd which specializes in the manufacturing
Concrete Plant International Vol. 5, pp36-38

and supply of the pre-cast concrete products such as pre-cast reinforced concrete u-shape open
drain, box culvert, pre-stressed concrete beam, pre-cast reinforced concrete square piles, pre-
stressed spun concrete pole and light weight block and others. The focus of this article is on the
constructability of bungalow house using IBS block work system which was constructed by Binaan
Desjaya Ltd.
Notwithstanding, the block work system is the simplest system and an affordable business for new
entrepreneur which involves with a small capital investment as compared with precast concrete
system that requires a big capital and large machineries to run the factory. In addition, the portability
and size of block work can be accessible to any place which is hard to reach due to factors such as
high hill topographic area and sub rural area.

LITERATURE REVIEW OF BLOCK WORK

Today, there are many types of masonry units that are available in the market which varies in
shapes and sizes. Clay bricks are the most widely used masonry units to construct brick wall in the
construction industry. In developing the construction industry, many alternative materials were used to
replace the clay brick, such as foam concrete brick (FCB). Deraman (2010) had study the block work
of Binaan Desjaya Ltd, where it is made from foam concrete bricks (FCB). In addition, it is still new in
the Malaysian market and still in the commercialise stage. FBC is widely used by other countries for
many years. The normal size of FCB is larger and the dimension does not comply with the standard
size of masonry brick stated in BS 3921:1985. FCB is a modern building material used as a
constructional element in low-rise building, and can function as an effective insulator. FBC is made
from organic material and incombustible. FCB is a light porous concrete, as a result of the hardening
of the mortar consisting of cement, sand, water, and foam. This foam provides the necessary content
of air in the concrete and uniform distribution of air bubbles in the concrete mass in the form of closed
cells. The foam is made of foam concentrate. FCB is inexpensive, economic, strong, ecologically
clean, biologically comfortable material; on quality it is closer to wood, fire resistance and is durable. If
the thickness of FBC is 100 mm, the resistance to fire is for 3.5 to 4 hours as compared to normal
concrete where the resistance to fire is for 1.5 hours.
FCB has a combine advantage of stone and wood: durability, lightness, workability and nail ability.
FCB represent an artificial cement stone with regular distributed closed pores. Such a structure
determines a high number of physic mechanical properties of the cellular concrete and makes it a
rather effective building material, which in comparison with other kinds of light concrete has the most
prospects for buildings. The most accessible and universal building material are the blocks of foam
concrete or the FCB, which are used both in construction, and for reconstruction of the existing
buildings and constructions.

METHODOLOGY

The methodology of the research is by using the qualitative approach of a case study bungalow
house. Based on Azman (2010a) research work using the case study approach, which is typically
developed or shaped up based on literature review, may yield deep into the studied case but may
produce narrow results. In a nutshell, case study is an important instrument to investigate the
construction process of a bungalow house and understand the current phenomenon by taking the
photographs. While the interview methodology could generate a deeper depth of the research field but
the scope covered is restricted to the knowledge and experience of those involved only. In addition,
with regards to the characteristic of respondents interview, they should have the good experienced in
their fields and have the most information to be shared (Patton, 2002). So only the selective
respondents should be catered in the interviews session in order to avoid the random respondent with
less information in order to save time and optimise on the cost involved in research project. As a
result, the limitation of each single approach has driven researchers to apply both approaches in order
to obtain optimum results of the studies.

RESULTS AND DISCUSSION

The construction of a bungalow house will include the lightweight block, lightweight pre-cast panel slab
and roof trusses without column. This construction design is unique due to the inclusion of ‘lintel
beam’. This special feature allows extra extension work or renovation to be carried out in the future.
Thus, the introduction of ‘lintel beam’ can dismiss the popular misconception of IBS system which can
Concrete Plant International Vol. 5, pp36-38

be never renovated. In addition to this, the use of IBS system has also proven its efficiency and
competency when the whole construction process of the bungalow only took 3 weeks to be completed
with a very minimal use of manpower.
2
The observation results of building a two storey bungalow house with 1800 ft area of construction
is shown in Figure 1 to Figure 12. While Figure 2 shows the construction of the raft foundation which is
cast in situ, which does not involve the IBS system. The unique feature of the construction is the
building of a staircase from block work as the vertical structure of the superstructure of the building as
shown in Figure 3. Usually construction work starts with the building of the wall but in this case the
method applied is vice versa. The staircase is build up until the first floor, which is build concurrently
with the raise of the block work wall as shown in Figure 4 and 5. In between the staircase and the
block work is the lintel beam which helps support the superstructure of the building. Next will be the
installation of the lightweight precast panel slab and completion of the block work wall until the second
st nd
floor as shown in Figure 6, 7 and 8. After the completion of the superstructure for the 1 and 2 floor,
the next step will be the installation of the roof truss and roof tiles by the conventional method as
shown in Figure 9, 10 and 11. The last stage involves the completion of the external work and the
building of a bungalow house is completed within 3 weeks as shown in Figure 12 and 13.

Figure 1. Selection of the type of house to

be constructed.

Figure 1 shows one of the existing house

models which can be selected by clients.
Clients can choose any models that they
like/prefer from the wide selection as long
as it suits the width of their land area.
During this process, the contractor will
provide assistance and advice to the client
to make sure that the client is able to make
a good and suitable choice.

Figure 2. Preparation of the raft foundation

for the house.

Before any construction can proceed, site

investigation will be carried out to access
general suitability of the site. For the
construction of this type of the house, raft
foundation is used as the basis of the
whole construction process. This is
because the site has low bearing capacity.
Thus, this method can help to reduce
differential settlement.

Figure 3. Construction of the staircases

using the lightweight blocks and the
lightweight pre-cast slab panels.

Once the raft foundation is completed, the

construction process can be executed. The
construction will use light weight block work
system. One of the prominent advantages
of this system is that the construction of the
staircases can be expedited.
Concrete Plant International Vol. 5, pp36-38

Figure 4. The construction of the

staircase up to the first floor.

The construction of the staircase can be

proceeded to the first floor level though the
main structure of the whole first floor is still
not being completed. The advantages of
using light weight block system is that it
does not require any precast concrete
column or cast in-situ concrete column.

Figure 5. Lightweight floor slab panel

installation.

When the construction of wall and staircase

is done up to the first floor level, the
construction of the first floor slab can be
proceeded. At this stage, light weight floor
slab panels are used to substitute the use
of cast in-situ concrete. Unlike the
conventional method this system does not
cause any material wastage from the use
of formwork, steel and concrete.

Figure 6. Completed lightweight floor slab

panels.

The use of light weight floor slab panels

can ensure accurate dimension during the
installation process. This is very important
because accuracy is essential in avoiding
materials wastage and overestimate on
materials required at the site for
architectural work. At the same time, this
process provides a more systematic and
organized wall and floor finishing.
Concrete Plant International Vol. 5, pp36-38

Figure 7. Lightweight blocks constructed

up to the first floor level.

Once the first floor level construction is

completed, the next stage can commence
immediately. The use of precast light
weight concrete does not required any time
duration for the concrete to reach its
targeted strength.

Figure 8. Light weight blocks for wall (with

st
opening) at 1 Floor level.
st
The construction of the 1 floor level can
be carried out smoothly despite a lot of
opening on the walls for the windows and
doors. This is possible because the light
weight block system has integrated the
openings in the design.

Figure 9. Installation of roof trusses in

progress.

The installation of roof truss and ceiling

frame can be done simultaneously. This
will save time and money, thus it will also
shorten the construction period.

Figure 10. Installation of roof tiles in

progress.
Concrete Plant International Vol. 5, pp36-38

Figure 11. Installation of roof tiles and

ceiling in progress.

Once the roof truss dan ceiling frame are

completed. The installation of roof tiles and
ceiling can be executed simultaneously.

Figure 12. External work in progress.

Figure13. The bungalow house is

completed within 3 weeks.
Concrete Plant International Vol. 5, pp36-38

CONCLUSION

On the whole, the construction process of the bungalow will only take 3 weeks to be completed.
Thus, it is evident that the use of light weight block system can expedite the construction process of
any building construction. At the same time, using this system can also minimise extension of time as
well as unfinished projects, which have been common problems in the conventional construction
process. In fact, this system can help to promote good image to the contractor due to its efficiency and
effectiveness, as well as cost effective. The research findings will benefit both the government and
private sectors in fulfilling the demand of IBS components in Malaysia.

The advantages of using the IBS technology in the process of construction and completion of a

 IBS materials are manufactured and installed under high quality standard control and
bungalow house are as follows:

 Construction period can be shortened;

supervision. Therefore the quality is not compromised;

 Work can be done efficiently because two works can progress simultaneously: at the work site

 Help to minimise the use of manpower at the construction site. This will reduce the construction
and the casting yard;

 Reduce construction wastage on the materials at work site. Thus site cleanliness can be
cost and the dependency on foreign workers;

 Renovation can be done by the owner because the design of the house can accommodate
monitored and maintained; and

renovation.

REFERENCES

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in Off-Site Construction Industry. Australian Journal of Basic and Applied Sciences, 4, 4478-
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Pacific Industrial Engineering and Management Systems Conference, 2010b Malacca,
Malaysia. University of Malaya Press.
DERAMAN, S. 2010. Investigation of Compressive Strength Foam Brickwall Panel with Different
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Malaysia Pahang.
ELLIOTT, K. S. 2002. Advances in precast concrete in mixed construction. Structural Concrete, 3,
145-154.
PATTON, M. Q. 2002. Qualitative Research and Evaluation Methods, Thousand Oaks, California,
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