Building technology 1 "Industrialized Building System" IBS
1. BUILDING TECHNOLOGY 1 (BLD 61403)
PROJECT 1
INDUSTRIALISED BUILDING SYSTEM (IBS)
PREPARED BY:
Dayang Nadrah (0323741)
Low Chi Yin(0329147)
Neville Geoffrey (0317780)
Nurul Shahira (0326500)
Vincentia Mutiara Kartika (0303496)
PREPARED FOR:
Ar Edwin Chan
2. CONTENTS
1.0 Introduction to IBS
1.1 System Comparison
1.2 Equipments Needed
2.0 Precedent Study
3.0 Proposed Building Systems
3.1 Precast System
3.1.1 Precast Column
3.1.2 Precast Beam
3.1.3 Precast Slab
3.1.4 Precast Wall
3.1.5 Precast Staircase
3.1.6 Precast Balcony
3.2 Steel Framing System
3.2.1 Steel Roof Truss
3.3 Blockwork System
3.3.1 Blockwork Wall
4.0 Schedule of Modular Components
5.0 IBS Score Calculation
5.1 Calculation
6.0 Working Drawings
7.0 Construction Process
8.0 References
3. 1.0 IBS SYSTEM
The Industrialized Building System (IBS) was first introduced to Malaysia in the 1960s. IBS
is a construction process that utilizes techniques, components, products or building
system which involve prefabricated component and on-site installation.
Open System - Components can be joined with other components that are pre-
fabricated from different manufacturers.
Close System- Can only be joined with the components manufactured by the same
manufacturer.
Five types of IBS used in Malaysia;
Precast System
Precast column, beams, slab, wall, 3D components (staircase, toilets, balconies, lift
chambers)
Steel Framing System
Steel beams and columns, portal frames, roof trusses
Prefabricated Timber Framing
Timber frames, roof trusses
Formwork System
Steel formworks, tunnel forms, beams and columns molding forms
Blockwork System
Interlocking concrete masonry unit (CMU), lightweight concrete blocks
ADVANTAGES
1. Minimized the number of labour needed to construct the building due to
simplified construction methods.
2. Reduce construction time due to the usage of standardized and simplified
components
3. Environmental friendly as less use of formworks on site
4. Lower total construction cost
DISADVANTAGES
1. Lack of aesthetic value due to standardized of components. IBS buildings are
mostly similar
2. Bad workmanship might caused problems on the joinery part
3. Lack of experience practicing or designing IBS by contractors or consultants.
INTRODUCTION
Figure 1.0.1 Construction process using prefabricated components or IBS
4. 1.1 IBS SYSTEM
INDUSTRIALISED BUILDING SYSTEM (IBS)
● Building components are manufactured in a factory then
shipped to the site to be constructed
● Cleaner construction process
● Lesser skilled labor needed
● Faster construction process as components are pre-fabricated
at the factory
● No space requirement for fabrication
● Higher industrialized quality
CONVENTIONAL BUILDING SYSTEM
● Building components are fabricated and constructed on site
● No transportation
● Proper, large free space required
● Alot of formwork and waste from construction process
● More labor needed
● Longer construction time. Construction depends on weather, if the
weather is not good, construction might stop and it takes longer time
for fabricated components to be dried.
COMPARISON OF THE TWO SYSTEMS
Figure 1.1.1 Prefabricated components Figure 1.1.2 On-site fabrication
5. 1.2 IBS SYSTEM
EQUIPMENT NEEDED
Cranes
Crane is a machine used to lift heavy components and transporting them to other
place or level.
Lifting Tools
Lifting tools or also known as lifting gear is an equipment attached to the crane
that can be used to lift and lowering loads of the pre-fabricated components.
Rigging Tools
Rigging tools (eg. Hook) is attached to the crane to carry the lifting tools
Figure 1.2.1 Mobile Crane Figure 1.2.2 Tower Crane (Min. 3 Stories High)
Figure 1.2.3 Spreader Beams Figure 1.2.4 Wire Rope Slings
Figure 1.2.5 Hook for the crane Figure 1.2.6 Shackles (Lifting point) Figure 1.2.7 Eye bolt (Lifting point)
6. 2.0 PRECEDENT
The Seri Jati Apartment located at Setia Alam,Shah Alam is classified as a low-cost
affordable apartment. The project is developed under the guidance of SP Setia.
Consist of 948 Units, a total of 6 blocks with the maximum height of 10 Storey
Apartment in a single phase development.
Reclines across an 18 acres land area with a built-up area of 813 sqft t. Provided it has
two parking spots with 2 elevators.
Figure 2.0.2 Seri Jati Layout Plan (6 Blocks)
Figure 2.0.3 Seri Jati Block Layout - Typical Floor Plan
SERI JATI APARTMENT, SETIA ALAM, MALAYSIA
Figure 2.0.1 View of Seri Jati Apartment
7. 2.0 PRECEDENT
SERI JATI APARTMENT, SETIA ALAM, MALAYSIA
Figure 2.0.4 Seri Jati Isometric
Construction system includes few conventional construction for foundation, ground floor, transfer
beam and RC slab as well as various precast components such as, precast load bearing and non
bearing wall, Precast staircases and landing slabs, precast lift core walls, Precast bathroom slabs and
precast air cond ledges. The roofing uses prefabricated steel roof trusses.
Figure 2.0.6 IBS Score for Seri Jati Apartment
Figure 2.0.5 Construction Progress of Seri Jati
END RESULT
1. No columns and projected beams
2. Consistent squareness
3. Consistent quality
8. Proposed Components
1. Precast Column
2. Precast Beam
3. Precast Slab
4. Precast Staircase
5. Precast Balcony
6. Precast Wall (External)
7. Blockwork Wall (Internal)
8. Prefabricated Steel Roof Trusses
3.0 PROPOSED BUILDING SYSTEMS
Figure 3.0.1 The Look of Proposed Building
9. 3.1 PRECAST SYSTEM
INTRODUCTION
The concept of precast (also known as “prefabricated”) construction includes those
buildings, where the majority of structural components are standardized and produced
in plants in a location away from the building, and then transported to the site for
assembly. These components are manufactured by industrial methods based on mass
production in order to build a large number of buildings in a short time at low cost.
ADVANTAGES
1. Very rapid speed of erection
2. Entire building can be precast
3. High quality controlled (Everything produced in factories standard)
4. Prestressing is easily done which can reduce the size and number of the
structural members
DISADVANTAGES
1. Skilled labour is required in the application of the components on site
2. Heavy machineries are needed to carry the components
Suitability
1. High rise - Most of components are the same, precast system is suitable for
this type of projects due to uniformity and fast installation
2. Developer housing - Design of houses from developers are mostly identical,
using precast system for this project type will save time in construction time
also labour cost
3. Low cost building - Lesser construction cost and labour
Figure 3.1.1 Manufacturing Process of Precast Components
10. 3.1 PRECAST SYSTEM
INTRODUCTION
MANUFACTURING PROCESS
1 2 3 4 5 6
The precast factory
often has specialist
workshops for the
manufacture and
maintenance of
moulds, and for the
production of jig-
built reinforcing
cages and
connections.
The reinforced cage
is positioned in the
partly assembled
mould, then the
remaining mould
section is completed.
Carefully specified
concrete is placed
into the mould. Many
precast works now
employ computer
controlled batching
plants.
To ensure that
optimum density is
obtained and that
specified strengths
are achieved,
concrete is placed
and compacted using
high-frequency
external vibrators or
pokers.
Once an appropriate
strength has been
reached, the precast
units are moved to
the storage area.
The components are
delivered to site in a
predetermined
sequence to ensure
that hardened
concrete are ready
for instant erection.
The components are
erected straight from
the lorry
11. 3.1 PRECAST SYSTEM
INTRODUCTION
FABRICATION PROCESS
1 2 3 4 5 6
Level and flatness of the
base mould should be
checked before
assembling the mould
for panel casting.
Ensure that the
dimensions of mould
are within specified
tolerance.
The mould should be
clean and free from
debris and old mortars
using remover or scaling
bars.
Checking that the
riber size ,spacing and
lap length are
accordance with the
drawings.
Check that the concrete
grade used is according
to design specification.
Proper vibration and
compaction should be
carried out in more
congestion areas.
Adequate curing time
should be observed and
desired environment.
Depending on the
anchor length of
inserts and type of
precast elements ie
thin floor slabs the
minimum concrete
strength required may
be higher to overcome
the suction and friction
forces during
demoulding.
12. 3.1.1 PRECAST SYSTEM
PRECAST COLUMN (STACKED COLUMN)
Precast Columns can be single-tier or multi-tiered as required. Use of precast columns
will expedite the project, as there is no requirement to wait for the curing as there is
with cast-in-situ columns. Column connections are often made using grouted sleeves,
but bolted or socket connections are also used.
DESIGN PROTOCOLS
1. Complete Customization
2. Multiple Applications
3. Rapid and precision structure installation
Figure 3.1.1.1 Precast columns on site
ADVANTAGES
1. Can be customized and designed to any specifications and fittings
2. Suitable for uniform construction finishes
3. Constructed 5 times faster than on site columns
Types of Precast Columns
Corner Column Extended Column Stacked Column
13. 3.1.1 PRECAST SYSTEM
PRECAST COLUMN (STACKED COLUMN)
Figure 3.1.1.2 Base connector
Figure 3.1.1.3 Column to column connector
1. Metal bearing plates and embedded anchor bolts are cast into the ends of the
columns.
2. After the columns are mechanically joined, the connection is grouted to
provide full bearing between elements and protect metal components from
fire and corrosion.
CONSTRUCTION SYSTEM
Ways to connect precast Columns to Foundation
1. Socket Connection 2. Starter Bars 3. Bolted Connection
Ways to connect precast column to column
One Typical Column-to-Column
Connection with Grout beneath the Base
Plate.
1. Column to column
stacked
2. Column to column
through beam connection
14. 3.1.2 PRECAST SYSTEM
PRECAST BEAMS (T-SECTION AND L-SECTION)
Precast Beams provide a flexible solution to the structural component of your project.
Precast Beams can be used for a number of applications from parking structures to the
structural framework of commercial buildings. Precast beams are perfect for
underground parking structures where the efficiency of the floor utilization can be
increased, reducing the size of the lot needed. Beams create an ideal framework for
hanging Precast Structural and Architectural Wall Panels and setting Hollow core floors
or solid slabs.
Figure 3.1.2.1 Precast beams joined with the columns
Types of Beam
DESIGN PROTOCOL
1. Require complex formwork to bear the weight of fresh concrete.
2. 7~28 days, so that concrete gains strength and carry the self load
3. This formwork requires time to erect and involves material inventory and also
large man power.
These are angled
notched beam that
support stadium riser
unit.
These are beams
cast with an integral
balcony.
Span over door or
window opens, to
provide bearing for
structure above.
Raker beam Balcony beam Lintel Beam
span around perimeter
to provide a bearing
edge on one side for
flooring slabs and
structure above
ADVANTAGES
1. Quality
The beam undergo effective curing and monitoring which makes it high level of
quality unlike on site pouring which is affected by dust.
2. Long life and low maintenance
Eliminates problem of leakage, cracks and reduces maintenance cost..
3. Easy Installation.
4. Energy efficient and recyclable.
15. 3.1.2 PRECAST SYSTEM
PRECAST BEAMS
Figure 3.1.2.1 Beams to Column Connection
1. Beams are set on bearing pads on the column corbels.
2. Steel angles are welded to metal plates cast into the beams and columns and
the joint is grouted solid
CONSTRUCTION SYSTEM
Beam to column pin
connection
Beam to column
welded
Bolted beam to
column connection
End to end Beam to
column connection
16. 3.1.3 PRECAST
SYSTEMPRECAST SLABS (HOLLOW CORE SLAB)
Figure 3.1.3.1 Types of precast slab
ADVANTAGES
1. Durable
With properties of high strength, low porosity and protection from the prestressing
reinforcement, they are long lasting units which consume lesser maintenance
1. Sound Proof Construction
Good sound insulation property
Types of Precast Slabs
1. Solid flat slab
2. Hollow core slab
3. Double Tee
4. Single Tee
Hardly any building materials available today offer the economy, flexibility and reliability
of precast, prestressed concrete. These slab units can be manufactured in various depths
in order to fulfill the diverse requirements for span and loading. Precast hollow core
slabs are typically 1200mm in width and about 20000mm in length.
DESIGN PROTOCOLS
1. Providence of standard span/ ratio depth to ease transportation and lifting.
2. Precast frames should be equivalent to cast-in-situ frames.
3. Design custom to service load or seismic load.
4. Sufficient cover thickness for fire resistance.
17. 3.1.3 PRECAST SYSTEM
PRECAST SLABS
CONSTRUCTION SYSTEM
1. Slabs are set on bearing pads on precast beams.
2. Steel reinforcing bars are in inserted into the slab keyways yo span the joint.
3. The joint is grouted solid
4. The slab may remain untopped as shown (figure 3.13.2), or topped with
several inches of cast in place concrete
Figure 3.1.3.2 Slabs to Beams Connection
Figure 3.1.3.3 Setting a Solid Slab on Beams
Figure 3.1.3.4 Grouting Process
18. 3.1.4 PRECAST SYSTEM
PRECAST WALLS
A method where concrete are molded into panels and are cured in a controlled
environment that then are brought to construction site to be assembled.
ADVANTAGES
1. Time saving for construction period
2. Rigid component that give a better strength for the structure
3. Water and fire resistance high
DISADVANTAGES
1. Can not be customized on renovation after construction.
- Precast concrete solid
- Precast concrete thin-shell panel
- Precast concrete sandwich wall panel
Types of Precast Walls
19. 3.1.5 PRECAST SYSTEM
PRECAST STAIRCASE
Precast concrete staircase is an ideal solution in constructing similar and repetitive
concrete staircase in a building. Precast concrete staircases are cast on their sides or face
down using mould with a fixed tread and riser. The quality of end product is then
assured.
Figure 3.1.5.1 Precast Staircase Being Installed
ADVANTAGES
1. Speed in installation and reduction in overall job
2. Rigid structure eliminates movement and possibility to creaks
3. Extended landing can be produced with variable length
4. Installation is not affected by adverse weather conditions
DISADVANTAGES
1. Efficient transport and lifting are prerequisite
2. Additional care is needed to achieve monolithic joints between precast stairs
and the cast in situ structure.
Types of Precast Stairs
DESIGN PROTOCOLS
1. Riser height should be limited to 165mm and 175mm
2. Recommended width of a standard staircase is to allow for a 100mm
clearance between handrails.
3. Are cast on their sides of face down using precision-engineered steel mould
and groove lines.
4. Should be suitable for fire escape.
- Precast concrete straight flight stairs
- Precast concrete cranked slab stairs
- Precast concrete open riser stairs
- Precast concrete spiral stairs
20. 3.1.5 PRECAST SYSTEM
PRECAST STAIRCASE
CONSTRUCTION SYSTEM
1. Hoist using a crane with four chains complete with shortening clutches
(Figure 3.1.4.2)
1. The type and size of cast in lifting points may vary
2. Plastic shims can be used as necessary to achieve correct level
3. Before installation, ensure that the bearing points are prepared and ready for
placement
4. All debris should be cleared from the stair so that no obstructions remain
5. Ensure any load bearing block work is at least 72 hours old and steelwork is
lined and leveled with bases grouted.
6. For installation, the stairs unit should be lifted upright, in the position that
they are going to be lifted.
Figure 3.1.5.2 Attaching U-Shaped Precast Stairs to Slab
Figure 3.1.5.3 Joinery System
21. 3.1.6 PRECAST SYSTEM
PRECAST BALCONY
Having a well designed balcony helps to change the face of how a building will look.
Balconies are attached at height giving the benefit of providing extra outside space and,
at the same time, creating a visual feature to a façade
Figure 3.1.6.1 Uninstalled Precast Balcony
ADVANTAGES
1. Rain water outlets can be incorporated into the finished balcony
2. Balconies can be erected with floor units prior to pouring screed
3. Ease of speed erection
Types of Precast Balcony
1. Cantilevered,
2. Fully supported or
3. Flying
DESIGN PROTOCOLS
1. Formstress to provide reinforcing starters for the nibs and they be cast on
site.
2. The cantilever steel can be cut short and Reidbar couplers fitted on site.
3. Ensure chains and strops are of the correct length and not more than 30
degrees of vertica
DISADVANTAGES
1. Very small margin for error
2. Connections may be difficult
3. Economics of scale demand regularly shaped buildings.
4. Cranes are required to lift panels
22. 3.2 STEEL FRAMING SYSTEM
INTRODUCTION
Steel framing system describes the the fabrication and erection of a steel skeleton using
vertical columns and horizontal beams. Steel is used more frequently in construction,
and is far more common in residential building. They are normally combined with
concrete floors or brick walls. The steel skeleton would than act as the main supporting
element of the structure. Usage of steel framing system in construction includes steel
beams and column, portal frames, roof trusses and more.
Figure 3.2.1 Steel Framing Construction
ADVANTAGES
1. A sustainable option for low-rise, mid-rise and high-rise building projects.
2. Easily erected once steel have been prefabricated.
3. Requires little maintenance and there are in no needs for treatment
considering they are not subjected to insect infestations.
4. Recyclable, suitable for the environmentally conscious.
DISADVANTAGES
1. Not heat resistant, there is potential of the members to weakening if
subjected to heat in an extended period of time.
2. Steel framed buildings have a high level of sound transmission.
3. Requires heavy machinery and a special trades and skills.
Types of Framing System
1. Skeleton Steel Framing
2. Wall Bearing Steel Framing
3. Long Span Framing
a . Girders
b. Truss
c. Arches
d. Rigid Frames
DESIGN PROTOCOLS
1. Members shall be in good condition
2. Damage members to be replaced or repaired
3. Use of suitable type of fastener for different requirements.
23. 3.2 STEEL FRAMING SYSTEM
INTRODUCTION
MANUFACTURING PROCESS
1. Selection of raw material
1. Prepping of steel, shearing and punch press
1. Forming press is done using a press break for consistent
and precise folding on frames as well as forming its final
shape
1. Welding process of addition feature such as hinges and
final welding is done to assemble and produce the frame.
1. Frame grinding and finishing is done by grounding and
sanding.
1. Paint and bake depending on custom frame
Figure 3.2.2 Raw material Figure 3.2.3 Forming press of steel
Figure 3.2.4 Welding of frames Figure 3.2.5 Grinding of spot weld marks
24. 3.2.1 STEEL FRAMING SYSTEM
STEEL ROOF TRUSSES
A standard truss is a triangulated system that resist distortion due to its
stable geometrical arrangement allowing even distribution of load across the members.
A truss system comprised of 3 members, a top chord, a bottom chord and an interior
members called webbing or webs. Majority of these roof trusses have webs that would
run at an angle between top and bottom chords. The gable-end truss is to be supported
along the entire length, and stabilized at the truss or wall intersection.
Figure 3.2.1.1 Industrialised Steel Roof
Figure 3.2.1.2 Standard Steel Roof Design
Prefabricated steel trusses offer a high-strength, lightweight roof system that can be
installed quickly. Most building roof can be framed with engineered light gauge steel
trusses which are manufactured from c-shaped metal studs. Steel roof trusses can
vary in design, an endless number of variation of the standard design are possible.
Figure 3.2.1.3 Truss system
ADVANTAGES
1. Suitable for low pitched roof
2. Sizes can be tailored
3. Easy assemble and disassemble, reduce carbon footprint
4. Long length high tensile metal roofing
Types of Roof Trusses
25. 3.2.1 STEEL FRAMING SYSTEM
STEEL ROOF TRUSSES
CONSTRUCTION SYSTEM
1. Fabricators used several tool to cut the steel of a truss, with the help
of plasma cutters, lasers and water jets. The metal fabricator
punches holes using high-pressure notches.
1. After cutting is done, forming is proceeded using both pressing
baking and rolling process.
1. Assembling process is welding pieces together to produces a steel
truss.
1. Truss is install depending on design.
Figure 3.2.1.4 Fabrication of steel trusses
Figure 3.2.1.5 Welding process
Figure 3.2.1.5 Trusses installation on site
26. 3.3 BLOCK WORK SYSTEM
INTRODUCTION
Blockwork system is a construction method that uses cement or concrete blocks. The
blocks are made from cement, aggregates, water and admixtures where the ratio of the
mixtures are adjusted according to requirements. These blocks are normally six times of
clay brick size.
Solid blocks Hollow blocks Cellular blocks Special blocks
Solid piece of
concrete casted
without any holes
on the surface.
Normally is used
on load bearing
construction and
exposed
structures.
Consists of one or
more voids
throughout the
block to improve
insulation
capacity.
Commonly used
for exterior or
retaining walls.
Block with one
and more voids
that penetrate
partially through
the piece.
Customized shape
which has unique
form and various
dimensions
compared to
standard blocks
for specific
purpose.
Types of Concrete Blocks
Figure 3.3.1 Blockwork construction in progress
MANUFACTURING PROCESS
1. Mixing all the materials consist of cement, aggregates, water and admixtures according to ratio and needs.
2. Molding Mixture is dumped into inclined bucket conveyor and transported to an elevated hopper. Mixture are compacted by hydraulic cylinder after second mixing process and then compacted
again with vibration. Mixture is let dry for certain period.
3. Curing Low pressure steam kiln is being used in this process. The concrete blocks are being held in the room with adjusted temperature for about 24 hours.
4. Cubing Cured concrete blocks are split into parts according to standard size.
27. 3.3.1 BLOCK WORK SYSTEM
BLOCKWORK WALL
CONSTRUCTION METHODS
1. Prepare footing by using timber base to build the mold then pour
concrete in it. . (Can be applied on precast beams.)
2. Spread mortar along corner to secure the positions of the
concrete blocks
3. Set corner block to adjust the boundary and limits for the
arrangement of the blocks.
4. Apply mortar around the base of concrete blocks being put to
secure the stability more.
5. Lay concrete blocks from edge to another edge to make sure the
arrangement of concrete blocks are correct.
6. Check alignment before stacking more concrete blocks any
further.
7. Apply mortar on top of the first row of concrete blocks as joints
between blocks.
8. Stack blocks on top of the mortar layer and repeat until certain
height.
9. Add reinforcements such as metal bars to make the wall stronger
and more rigid.
ADVANTAGES
1. Cost efficient, less energy consumed
and time saving
2. Excellent sound insulation.
3. Good option for dry lining wet finishes
and fixing.
DISADVANTAGES
1. Lower strength
2. Lower water resistance
3. Less load bearing properties due to
limited storey of buildings application.
Figure 3.3.2 Blockwork construction in progress
29. 5.0 IBS SCORE CALCULATION
ABOUT
Ground floor = 312m2
First floor = 312m2
Second floor = 312m2
AREA OF CONSTRUCTION
Columns : Precast concrete square columns
( m2)
Beams : Precast concrete L-beams and T-beams (
Floor slabs : Precast
Roof truss : Prefabricated steel roof trusses
STRUCTURAL SYSTEMS
Block work :
WALL SYSTEM
OTHER SIMPLIFIED CONSTRUCTION SOLUTION
Columns : %
Beams : %
Floor slabs : %
Roof truss : %
Wall : %
STRUCTURAL SYSTEM WALL SYSTEM OTHER
The objective of the manual is to provide a well-structured assessment system for
calculating the IBS Score. It sets out the IBS Score formula, the IBS Factor for each of the
elements used in the building, methods of calculating the IBS Score, explanatory notes,
as well as sample calculations. It is also intended to provide complete guidance for every
professional to evaluate the IBS Score for any building project.
47. 8.0 REFERENCES
1. Precedent Studies, IBS Scoring in Malaysia, 25th April 2018, Available on http://rehdainstitute.com/wp-content/uploads/2017/05/4.-Kow-Choong-Ming.pdf
2. Steel Framing System, The Constructor Civil Engineering Home, 26th April 2018, Available on https://theconstructor.org/structural-engg/types-structural-steel-framing-
systems/18554/
3. Steel Framing System, Light Steel Framing Design System Standard, 26th April 2018, Available on
https://kupce.ku.edu/sites/kupce.ku.edu/files/docs/cpep/structural/speaker-presentations-2017/LaBoube.pdf
4. Laboub. R, American Iron and Steel Institute retrieved from, https://www.wbdg.org/guides-specifications/building-envelope-design-guide/wall-systems/precast-
concrete-wall-systems
5. Block work System, https://prezi.com/yvmdbgcguvay/blockwork-system/
6. Block work System, https://www.slideshare.net/doogstone/blockwork