CHAPTER 1

INDUSTRIALISED BUILDING SYSTEM

Sushilawati Ismail, Mohamad Azri Saharum and Erieka Nesha
Faculty of Civil Engineering & Built Environment,
Universiti Tun Hussein Onn Malaysia, Parit Raja, 84600 Johor, Malaysia.

1.1 DEFINITION &TERMINOLOGY

Industrialised Building System (IBS) is a dominant terminology, particularly embraced

by Construction Industry Development Board (CIDB) of Malaysia that represents the
application of construction industrialisation through prefabrication, precast component
and/or off-site construction. IBS is a modern construction technique that involves the
installation of precast components in a controlled environment such as construction sites
or factories. This construction system uses prefabricated components manufactured at the
factory based on orders from the contractor. The examples of building components
include walls, floors, beams, columns, stairs and veranda floors. The components that
have been manufactured at the factory will then be transported and installed at
construction sites until it becomes a complete building structure. This construction is
based on the concept of pre-manufactured method.

Looking forward to the evolvement of IBS concept from a global perspective, it should
be expanded to modularisation and hybrid construction approach (Anuar et al., 2011).
There is a diversity of terminology used to interpret the concept of IBS in construction
practices as shown in Figure 1. Jaillon & Poon (2009) and Tam et al., (2007) used the
terms of “fabricated building system”, prefabrication and prefabricated
building/component interchangeably for standardised modular design building that
adopted pre-casting techniques with a high level of repeatability. Arif & Egbu, (2010),
Blismas et al., (2006), Boyd et al., (2013, Pan & Sidwell, (2011), Pan et al., (2007) and
Zhai et al., (2013, 2014) have used the term “off-site construction” to represent the
concept of modern construction method that change a part of on-site construction
activities such as in-situ concrete casting into a manufacturing environment prior
transport and assemble at the building location. Since the component production process
about manufacturing, therefore, “industrialisation” and “industrialised
building/construction” are another terms referred by Ågren & Wing, (2014), Larsson et
al., (2014), Schmidt et al., (2014), and Zhang & Skitmore, (2012) to exemplify the
standardisation in structure component design and production process. Regardless of the
multiple definitions and terms used, Anuar et al., (2011) revisited on the extensive
definition of IBS as an innovative construction system that has at least two of the
following characteristics : (i) industrialised in transportation, production and assembly,
(ii) mass-production, (iii) on-site fabrication, (iv) standardisation and structured planning
and (v) integration of the processes, as shown in Figure 1.

Figure 1: Interpretation of IBS definition

1.2 CONCEPT OF IBS

What made IBS different to conventional construction method?

Firstly, component production is the major phase in the industrialisation process. It is

carried out under a controlled environment and is usually located away from the
construction project site (also known as off-site construction); while in some projects,
prefabricated components are produced in a casting yard located inside the project site.
However, both approaches eliminate cast-in-situ activities.

The second element is the transportation of the components to the construction site. The
delivery of components is comprehensively scheduled to arrive on-site in the correct
amount and sequence so as not to overload the limited space of the project site. Depending
on the construction site location and condition, scheduling and regulation may be required
as part of the logistics planning (Antunes & Gonzalez, 2015).

Thirdly, following the component delivery, installation then takes place by hoisting,
erecting, and assembling the components to build the structure using automation and
mechanisation approaches. Depending on the materials used, the component assembly
may require an appropriately designated mechanism of joint connection to complete the
structure.

The component production, delivery, and installation eliminate the issue of cast-in-situ
found in conventional construction methods. These made the project life cycle of IBS
project a bit different from the conventional practice as shown in Figure 2. It can be seen
that after the design stage, there are additional stages of component production and
transportation before the construction stage can be started.

Figure 2: Project life-cycle for IBS-based project.

1.3 IBS CLASSIFICATION

In Malaysia, the Construction Industry Development Board (CIDB) has classified IBS
into six categories, namely steel frame system, timber frame system, block work system,
precast system, formwork system and innovative system.

1.3.1 Precast System

The precast concrete system is the most popular IBS used in the Malaysian construction
industry. There are several types of component’s category under this system includes
precast concrete framing, concrete panel and concrete box system. The components
available for the frame structure are beams, columns, slabs and the non-bearing wall while
for the system that considered as load-bearing consists of slab and wall panels (See Figure
3). Column and beam are the main structural members that hold the load of the buildings.
Similarly, the load-bearing panel carries load distribution over its span. This system is
suitable for the buildings that require many rooms such as multi-storey residential
buildings, hotels and hospitals.

In addition, concrete box system which is also known as a modular system also classified
under this category. It is representing three-dimensional concrete modules that
prefabricated or pre-assembly into one unit of building element. The common elements
that using such system are balconies, staircases, toilets and lift chambers.

According to Hamid et al. (2011) precast system requires critical attention during erection
and installation process. The connection between precast component as well as services
fitting need proper coordination to avoid mishandling that may cause re-work. Therefore,
the main contractor and sub-contractors have to have good communication and mutual
understanding.
 Figure 3: Types of precast components (Source: Eastern Pretech (Malaysia) Sdn Bhd)

1.3.2 Steel Framing System

Steel frame systems are commonly used with precast concrete floors, columns and steel
beams. The structural components of the steel frame system are divided into two types
based on the processes and materials in the production which are hot rolled steel and cold
rolled steel.

Previously, this system is mostly applied for industrial facilities and commercial building,
especially the utilisation of roof frame structure as shown in Figure 4. However,
nowadays this system is also popular in the construction of housing unit even skyscrapers.
The application of steel for such projects is not limited to roof trusses anymore, but as
superstructure elements as well. For example, the construction of Petronas Twin Tower
and most recently, the Exchange 106 (Figure 5) in Kuala Lumpur used steel framing
system for their superstructure, whereas these buildings were erected and built very
quickly (CIDB, 2018). Similarly, a case study of building an 800sqft house that using IBS
steel framing took only seven days to be completed (Mohammad et al., 2018).

The utilisation of steel framing system promotes buildability and simplicity. The advance
technology of installation process using automation especially could accelerate the
project completion. However, it is important to ensure the project scale is large enough
to encourage cost savings.

Figure 4: Example of steel frame system of roof trusses (Source: https://bestweld.com.my)

Figure 5: The Exchange 106

1.3.3 Timber Framing System

The wooden frame system is the least used system in the construction of buildings in
Malaysia that use the IBS system. This timber frame system consists of wooden building
frames and wooden roof trusses. The system also has its unique market value and offers
attractive designs from simple residential units to buildings that require high aesthetic
value such as chalets for resorts.

Most of the use of this system in Malaysia is for the construction of roof frame structures.
Important to realise, since hundreds of years ago, a traditional timber Malay house (see
Figure 6) was already used this system in crafting their home with the concept of
repetition. There are also other examples of residential construction that uses this system,
namely the old Sri Menanti palace located in Negeri Sembilan where the manufacture of
the palace uses a method of mortise without nails to join the timber.
 Figure 6: Traditional Malay house adopted repetitive timber framing system since ages.

Figure 7: Heritage building of Sri Menanti Palace (Source:http://www.heritagemalaysia.my)

1.3.4 Block Work System

Block work system is one of the types of IBS using precast concrete technology. Hollow,
bonded and precast foamed concrete blocks are included in the category for block
systems. This method is better known as the interlocking components (see Figure 8 and
Figure 9) of concrete bricks or lightweight concrete blocks. Because of its small size
compared to other IBS components, it can be easily managed. Many of these types of
blocks are also often built on-site because they are simple and have a low production cost.

Figure 8: Example of interlocking concrete blocks

 Figure 9: Application of a block system for low-cost housing

1.3.5 Reusable Formwork System

Reusable formwork system used to replace the conventional timber framework. As the
timber formwork would generate high construction waste due to its low reusability,
finding a better alternative is necessary. Substituting the conventional formwork material
like timber into a longer-life material such as steel is a better option. Therefore, the
reusable formwork system was introduced. This system considered as one of the low-
level or the least prefabricated IBS, as the system generally involves site casting. This
system can be used for beam, column, wall and slab formworks. The advantage of this
system is that walls and slabs can be produced simultaneously using the tunnel formwork
method. Apart from steel-based formworks, plastic and aluminium formworks are also
widely used for this method nowadays.

The steel formwork system uses a systematic way to carry out the construction process.
This is because the formwork panels that have been used can be reused for other
construction projects. For a building project which considered as extraordinarily complex
geometry like Sarawak State Legislative Assembly building (see Figure 10), application
of IBS by using this system was desirable (CIDB, 2017). Besides promoting resource
optimisation through reusability, steel formwork provides better finishing and precision
casting.

Figure 10: Sarawak State Legislative Assembly building.

The formwork system also runs the construction process systematically and
mechanically. Using a reusable moulding panel, concrete construction on the site can be
improved. It speeds up the construction process through rapid hardening concrete. The
cost can be reduced by standardising the size of the structure and ensuring that the
production cycle is smooth. It also recognized that this system subjected to structural
quality control, the products offer high-quality finishes and fast construction with less site
labour and material requirement (Din et al., 2012).

1.3.6 Innovative System

The application of industrialisation concept has emerged in the construction innovation.

Boyd et al., (2013) introduced unitised building (UB) concept which adopted the off-site
construction approach as a resolution to short-term lodgings for buildings (see Figure 11).

Figure 11: Relocatable pod for temporary lodging (Boyd et al., 2013)

On the other hand, by employing SMLsystem, Serra Soriano et al., (2014) proposed a
modular house which designed with prefabricated and industrialised elements that built
by assembly activity instead of construction. The enclosure of the modular house as
shown in Figure 12 was designed for being flexible with dismantling and reconnecting
ability to allow future changes of space size or design. Crowther (2005) in his design for
disassembly (DfD) guide proposed the utilisation of interchangeable building parts, using
modular design, prefabricated sub-assemblies and mass-produced system. These kinds of
components provide the disassembly ability of a constructed building to improve the
future resource recovery rate. These particular strategies are a part of IBS characteristic
of modularisation, prefabrication and off-site production construction methods.

Figure 12: Decomposition of the flexible enclosure (Serra Soriano et al., 2014)
1.4 IBS MOVING FORWARD

IBS is increasingly adopted in the Malaysian construction industry. It has been recognised
as the construction technology that contributes to productivity improvement and
environmental preservation. IBS was found to be practically implemented in the
construction of multistorey residential and commercial building project (Boyd et al.,
2013; Jaillon & Poon, 2008; Lawson et al., 2012; Lee et al., 2014) which the concept of
standardisation, repetition and prefabrication was recognised as shown in Figure 13.
However, nowadays, IBS application can be found in landed residentials includes
bungalow, terraces and semi-D.

Figure 13: Multistorey IBS buildings (Source: http://www.setiaprecast.com.my)

Unlike buildings, infrastructure displays less popular in IBS application even though such
project already implemented the system far earlier. Larsson et al., (2014) stated that a lot
of component and subsystem are commonly standardized and prefabricated as shown in
Figure 14. For instance, the application of prefabricated component such as decks, piers,
abutments, walls and girders for accelerated bridge construction has removed cast-in-
place activities (Hällmark et al., 2012). This could minimise site activities, reduce time
consume and provide a safer work environment. Although it is only applicable to limited
elements, adoption of prefabrication promotes the project cost-effectiveness, time
efficiency and sustainability.
 Product Component

Steel bridge Edge beam (bridge)

Concrete bridge Reinforcement
Barrier & retaining wall Casting Mould
Cut & cover concrete tunnel Deck slabs (bridge)
Standardisation &
Prefabrication
Foundations (bridge and tunnel)
Superstructure (bridge)
Tunnel lining

Subsystem

Figure 14: Products, subsystems and components of infrastructure identified as being suitable for standardisation
and prefabrication (Source: Larsson et al., 2014)

The prefabricated technologies are not restricted to concrete only, but steel and timber as
well. According to Larsson et al. (2014), tunnel lining, noise barrier, retaining wall, edge
beam, bridge foundation and permanent concrete casting mould, are the other appropriate
components that could be standardised and prefabricated using not only concrete but steel
for the reinforcement.

Figure 15:Application of IBS in old and modern bridges

As steel and cement consumption was expected to remain high in the future for
infrastructure and building maintenance, effective uptake innovations in construction
technology are essential, not only to reduce the material consumption intensity (Shi et al.,
2012) but also to improve project performance (Rose & Manley, 2012). For example,
industrialisation construction technologies have to be implemented via closed-loop
phases of design, production, assembly and disassembly (Pons & Wadel, 2011). Go et al.,
(2015) suggest that consideration for disassembly, recycling, reuse, remanufacturing,
refurbishment or repurposing might go beyond one life-cycle. However, life cycle design
approach such as DfD (designed for deconstruction) and IFD (industrialised, flexible and
demountable) were found seldom practised yet.

1.5 CONCLUSION
IBS is usually associated with the construction of multistorey buildings, such as
residential buildings, commercial or office buildings, and schools. This misconception of
IBS implementation being limited to building projects is occurring across the local
industry, which is not surprising. This may be due to the early years of IBS initiative, in
2005, when the Malaysian Government promoted IBS usage through the mass
construction of low-cost houses. The focus is more towards multistorey building projects,
as such projects have high IBS potential due to the repetitive nature of production (CIDB,
2010). While the term “IBS” has been embraced by the CIDB, it does not specify the
types of construction projects to be involved. Through similarities, recognition among
project, and the exploration of repetitiveness and standardisation opportunities could
encourage industrialisation practices in Malaysia construction industry.

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