4. 1. CONCEPTS AND FRAMEWORKS
1.1 PROPOSED IBS SYSTEM
Industrialized Building System (IBS) is a technique of construction whereby components are manufactured in a controlled environment, either offsite or in situ,
and then transported and assembled into a structure with minimal additional site works. The main advantages of IBS adoption in construction activities, offer
higher quality and aesthetic value of products, cleaner and safer construction site, faster construction, lower total construction costs of ownership, and more
design standardization. The government had started its first projects on IBS with the goal of speeding up delivery time and building more affordable yet better
quality houses. The use of IBS reduces the construction process at site, as the formwork of IBS components allow repetition of elements thus consequently
leads to the increase of productivity and modular coordination. The components are dimensioned and positioned in terms of basic modules as to ease in
construction.
There are five main types of IBS categories used in Malaysia, which are precast system, formwork system, steel framing system, block work system, and
prefabricated timber framing. Our apartment design uses mostly precast concrete components in addition of prefabricated steel trusses and purlin.
1.2 PREFABRICATION PROCESS OF IBS COMPONENTS
● Selection of Mould, Rebar, and Main Connections - Precast factories include specialist workshops for the manufacture and maintenance of moulds, rebars,
and connections for different building components.
● Mould and Rebar Setting - After the assembly of moulds, rebars are set and positioned into the mould to help strengthen and hold the concrete in tension.
● Concreting - A mixture of concrete is then poured into the mould, with the employ of computer controlled batching plants.
● Compaction of Concrete - Concrete is placed and compacted using high-frequency external vibrators or pokers to ensure that optimum density is obtained
and that specified strengths of the concrete are achieved.
● Storage - Once an appropriate strength has been reached, the process of striking formwork is done. The precast units are then moved to the storage area,
where they are handled within hours of casting as part of the rapid production cycle.
● Transport to Site - The components are delivered to site in a predetermined sequence to ensure that hardened concrete are ready for instant erection.
● Erection at Site - The components are erected immediately upon arrival, which leads to faster construction time.
3
5. 1.3 SEQUENCE OF CONSTRUCTION
4
Precast Foundation Prep - Preparation work for the foundation starts with excavat in1g the soil located in
betvi/een the reinforced concrete pil,es t o begin wi:th the construction of the a[Partment. The ground
leveling is aligned to ensur,e precast pad footings are,t o be nn the correct position along 1.vith its protruding
column stumps.
Pr,ecaist Columns to Found.at ion - The precast: column is then casted on top of the precast column stumps
l'llith the use of steel formwork. They ar,e then bolted on the footings with he joint connection is cast ed
v1.1iith concrete. The r,ebar in the core of the columns help create a secu:r,e joint betvi1een the column and
foundation.
Precast Beams to Column - Precast beams are then placed and cantHevered on top of the ,col1._qmn 001rhels
and is. s,ecureiy connected to the collumn,
,,_
[
6.
5
Hollow Core Precast Slabs - HloUmv core pr,ecast floor slabs are then placed on top of the precast beams.,
w1ith steell r,ebars imerted on between t he slab s. Both components are then secur<ed by grouting wirth
cement.
Hollow Core Precast Wallis - HollO'w core pr<ecast slabs are used as Vi!alls. and floorings in this design as they
are preferable due to the ease of ducting and reduced weight from its long oonti uous hollow cores.
Hollow core prrecas.tv,ralll panels are put into place and connected t hrough fi,eld plates before being grouted
v11nth cement t o s,ea1I and cover the recessed connection..
Upper Level.Construction - Upper levels of the building .are then const ructed by connecti ng col~m11 to
column and grouted with cement, just as how the lower level of columns are connected to the foundation..
Preca:st Staircase - Preicast staircases with anchor p'lat es are positioned and slotted onto the !landing~where
the gaps are secured and grouted with cement. The staircase landing is. then connected t o the precast wall
through L-angled plat e oonnectors.
Bal'cony Slabs and Railings - Railing posts are inserted and connected to the lbaloony slabs. by metal base
plat es to firmlly secure in place. The overall components are then slotted into the be,ams.
7.
6
Roofing ln.Jsses and Pm lins - The apartment building is desrgned with g op,en gable roof; pr,efa'brucat ed roof
t russes are,us,ed and secur,ed to the beams using IL-brackets connectors, whereas prefabricated purliins are
bolted onto the rafter.
8. 1.4 CASE STUDY
Government Apartments, Putrajaya
The apartments located in Putrajaya, the federal administrative capital of Malaysia, has been a project planned by
the Malaysian Government to provide suitable accommodation for the employees working in government
departments in Putrajaya. The project has marked a notable significance as it supports the Government’s efforts in
promoting the use of Industrialized Building System (IBS) technology in construction. The apartments, five blocks of
16 and 19 storeys, are complemented with a total of 548 apartment units and amenities such as car parks,
playgrounds, and multi-purpose halls. Rapid speed of construction has been achieved in this project where a rate of
four units per day was able to be erected due to its use of precast concrete walls.
Sekolah Kebangsaan Brickfields (1),
Kuala Lumpur
Sekolah Kebangsaan Brickfields (1) is a national school located at Jalan Sultan Abdul Samad, Brickfields, Kuala
Lumpur, where it has been a place for education for young Malaysians for 50 years. Initially completed in 1954, the
school was completely demolished in February 2003, to make way for a newer four-storey school building in its
place. The compact design houses two schools in a total site area of 4,488 m2
. The project has 75% of its building
components prefabricated, such as precast columns, beams, staircases, and hollow core floor slabs. Due to its
repetitive elements and rapid construction of precast components, the construction period the lasted about 7 ½
months, with its completion date by 17th September, 2003.
7
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DOOR SCHEDULE
TYPE WIDTH HEIGHT (mm) THICKNESS (mm) QUANTITY
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