Building Technology Project 1

BUILDING TECHNOLOGY I [BLD61403]
Industrialised Building System IBS (Precast Concrete)
Tutor: Mr. Mohamed Rizal Mohamed
Goretty Lee Pey Shy
Ong Yi Teng (Crystal)
Serene Lim Jia Yi
Joslyn Siew Zi Tong
Toh Yi Lin
0326837
0326486
0334258
0334488
0327984

CONTENT
3.0 TECHNICAL DRAWING
3.1 Architectural Drawings (Scale 1:100)
3.1.1 Level 1-3 Plan
3.1.2 Roof Plan
3.1.3 East Elevation
3.1.4 West Elevation
3.1.5 North Elevation
3.1.6 South Elevation
3.1.7 Section A-A’
3.1.8 Section B-B’
3.2 Structural Drawings (Scale 1:100)
3.2.1 Level 1-2 Structural Plan
3.2.2 Level 3 Structural Plan
3.2.3 Roof Structural Plan
3.2.4 Level 1-3 Floor Slab Structural
Plan
3.3 3D Drawings (N.T.S)
3.3.1 Axonometric
3.3.2 Roof Exploded Axonometric
3.3.3 Sectional A-A’ Perspective
3.3.4 Sectional B-B’ Perspective
1.0 INTRODUCTION
1.1 Introduction to IBS and HIstory of IBS
1.2 Types of IBS in Malaysia
1.3 Advantages and Disadvantages of IBS
1.4 Standard Design Workﬂow of IBS
1.5 Precast Concrete System
1.5.1 Types of Precast Concrete System
1.5.2 Advantages and Disadvantages of
Precast Concrete System
1.6 Case Study : Hospital Kuala Lumpur Car
Park
2.0 CONCEPT AND FRAMEWORK
2.1 Proposed IBS System
2.2 Precast Slab
2.3 Precast Column & Beam
2.4 Precast Concrete Wall
2.5 Precast Concrete Staircase
2.6 Prefabricated Bathroom Pod
2.7 Prefabricated Steel Roof
2
4-11
12-19
20-38

CONTENT
5.5 King Post Roof Truss Joint Connection
5.6 Connection detail of King Post Roof Truss
5.7 Construction Sequence of Prefabricated
Bathroom Pod (Installation with Rollers)
6.0 IBS SCORE CALCULATIONS
7.0 CONCLUSION
8.0 REFERENCE
3
58-59
60
61-63
4.0 SCHEDULES OF IBS COMPONENTS
4.1 Prefabricated Steel Roof
4.2 Prefabricated Window
4.3 Precast Hollow Core Concrete Slab
4.4 Prefabricated Door
4.5 Precast Concrete Staircase
5.0 CONSTRUCTION DETAILS
5.1 Construction Sequence of Slab, Beam &
Column
5.2 Connecting Detail of Slab, Beam & Column
5.2.1 Column to Footing
5.2.2 Column to Column
5.2.3 Beam to Column
5.2.4 Slab to Beam & Slab to Slab
5.3 Construction Sequence of Precast
Concrete Staircase
5.4 Connecting Detail of Concrete Stair
5.4.1 Stair to Floor
5.4.2 Landing to Down Riser
5.4.3 Landing to Wall
5.4.4 Landing to Up Riser
39-47
48-57

1.0 INTRODUCTION
1.1 Introduction of IBS and History of IBS
Introduction of IBS
▪ a process that utilized technique of construction, which all the components such
as wall, slab, beam, column & staircase are manufactured in a controlled
environment.
▪ the components are premade in a factory and then assemble it on-site or at site
factory under restrict quality control.
▪ 1998- people define IBS as a manufacturing production in order to minimize
source of waste and enhance the end user.
▪ 1986 -known as an industrialize process which component are conceived,
planned, fabricated and transported and assemble on site.
▪ In Malaysia people known IBS as a prefabricated or pre-fab construction and
morden method of construction (MMC).
▪ two type of system component exist in IBS, there are software component and
hardware component.
▪ Software component are elements include system in designing. They need to
study the requirement of the end user and take note of market analysis, to
development of standardized components, establishment of manufacturing, the
assemble layout, process, allocation of resources and materials and definition of
building designer frame work.
▪ Hardware component have three different process which are formwork and
beam system that carry loads through beams and girders to column and to the
ground. Panel system load are distribute through large floor and wall panels. Box
system that employ three dimensional module for prefabrication of habitable
unit that are capable of withstanding load from direction due to their stability.
1624
Introducing of the IBS in the european countries and the United States.
1963
IBS was initiated in Malaysia when the Ministry of Housing and Local Government
made visits to several European municipalities with the objective of assessing
their housing development plans. It was to explore the the concepts of
development in these countries in further detail.
1964
Malaysia government launched a project to test the efficiency of the IBS. The key
objectives looking to be fulfilled include the acceleration as well as the increase
of affordable housing of substantial quality here in Malaysia.
Present
As reported, there are 21 different manufactures and suppliers that are
promoting their components in Malaysia. An IBS centre has also been
established in Jalan Chan Sow Lin, Cheras, Kuala lumpur who are responsible for
implementing strategies and introducing breakthroughs in the IBS technology to
improve its performance and quality in the construction industry as well as to
reduce dependencies on foreign labour.
History of IBS
4

1.0 INTRODUCTION
1.2 TYPES OF IBS IN MALAYSIA
To ensure the industrialised building system more systematic and mechanized in Malaysia, the IBS classified into 6 main types by CIDB.
These 6 main IBS known as bring popularly used in Malaysia.
Precast concrete framing, panel and box
system
The precast concrete elements are concrete products
that are manufactured and curved in a plant environment
and then transported to a job site for installation. This IBS
consists of precast concrete columns, beams, slabs,
walls, 3D components (i.e. balconies, staircases, toilets,
lift chambers, refuse chambers), lightweight precast
concrete and permanent concrete formworks.
Steel formwork system
The steel formwork id prefabricated in the factory and
then installed on site. This IBS is made up of tunnel
forms, beams and columns moulding forms, and
permanent steel formworks. This system is the least
prefabricated amount in IBS, as it normally involves
site casting. Therefore, it is subject to structural
quality control, high-quality finishes and fast
construction with less site labor and material
requirement.
Prefabricated timber framing system
Timber framing system included timber building
frames and timber roof trusses. Although the latter is
more common, timber building frame systems also
offer interesting design form simple dwelling units to
buildings such as chalets for resorts.
Steel framing system
This IBS commonly used with precast concrete slab,
steel columns/beams and steel framing systems and
ies used extensively in the fast-track construction of
skyscrapers. Apart from that, it is extensively used for
light steel trusses consisting of cost-effective profiles
cold formed channels and steel portal frame systems
as alternatives to the heavier traditional hot-rolled
sections.
Blockwork system
The elements of block work system consists of
interlocking concrete masonry units (CMU) and
lightweight concrete blocks. This system is widely used
for non-structural wall as an alternative to conventional
brick and plaster.
Innovative system
This IBS combine multiple category of IBS, such as
prefabricated with precast , blockworks with
prefabricated, precast with brickwork to achieve better
design, cost saving, energy efficiency and building
friendliness to specific requirements by owners are very
common nowadays in Malaysia too. Some of the new
materials introduced in IBS include gypsum, wood wool,
polymer, fiberglass and aluminum-based IBS
components.
Figure 1.1 Precast Concrete Wall Panel.
Figure 1.2 Innovative System.
Figure 1.3 Blockwork System.
Figure 1.4 Steel Formwork System.
Figure 1.5 Steel Framing System.
Figure 1.6 Prefabricated Timber Framing System. 5

1.0 INTRODUCTION
1.3 ADVANTAGES & DISADVANTAGES OF IBS
Advantages
1. Saving in labour at site
When the IBS components are produced in factory, higher degree of utilisation if
machine is permitted and the use of labour will be reduced lead to saving in labour
cost. It also will reduce the construction process at site and consequently reduce the
number of labour required at site.
2. Reduce construction period of time
Faster completion of projects due to advanced off-site preparations and simplified
process. Off-site production can start while the construction site is under earthworks.
This offers earlier occupation of building.
3. Reduce monetary losses
IBS are manufactured at the factory, thus usage of machineries on site can be cut off.
Besides, reducing on-site workers significantly reducing labor cost for constructors.
Cost of transferring waste materials can be minimizing due to quality control and
reducing waste material.
4. Consistency of high quality product
As most components are manufactured in the factory, the quality of the components
can be consistent and maintained as the working environment in the factory is easier
to control. Skilled workers with specific scope of works improve efficiencies and
reduce errors.
5. Reduce waste stage
Adoption of IBS element result in less construction process especially wet work at the
site. Thus, a more organized and safer work platform are provided due to reduction of
construction waste, site workers, and prefabricated construction materials.
6. A safer environment for worker
The use of IBS will decrease construction waste on site such as concrete and
formwork. Minimizing the use of formworks and props at site because of casting in
factory.
It is important for Malaysia construction industry to evolve and be ready for globalization era whereby increase of productivity, quality and safety are compulsory and the reduction of
cost and construction period must be considered. According to CIDB (2003), compares to the conventional construction method. IBS has the following advantages:
Disadvantages
1. High initial capital cost
The IBS construction requires a high initial investment capital for the
purchase of machineries, steel mould, foreign technology, transportation
and wages of skilled workers for the installation process. The extra cost
involved in the training of foreign unskilled and semi-skilled laborer to
enable them to involve in the IBS construction process.
2. Monopolise the market
The IBS will enable the construction and manufactures that implement this
technology to monopolise the market.This is because many companies are
still reluctant to change due to high investment cost. Then the small and
medium industries that are reluctant to change will be affected and this will
result in an unhealthy competition among them.
3. Site accessibility
The site condition will affect the use of IBS. Since the IBS components are
transport to the site and involves heavy machineries for the installation
process. The site must have fair road surface and temporary site access for
heavy vehicle and therefore, the road condition have to be improved the
construction process.
4. High cost transportation
It need to have a good road and need to require the weight that carried on
the lorries as well as the time that are suitable for transportation.
6

1.0 INTRODUCTION
1.4 STANDARD DESIGN WORKFLOW OF IBS
Design considerations
Recognizing and analyzing the design, determining the conditions, considering the productivity and optimizing the layout.
Manufacturing
Tally with the standard dimensions of the manufactured components. The manufacturing process are based on the schedule
and construction process.
Delivering
The manufactured components are then shifted to the site for assemblage. At the preliminary stage of production, the size of
the components must take into account so that the components can ﬁt into the turck efficiency.
Completion
Finished of the building happens at this stage. The facade of the building is painted and coated to improve the aesthetic quality
of the building.
Assembly
Once the components arrived on site, they are assembled quickly to reduce time wastage. These components are assembled
together into a complete unit.
7

1.0 INTRODUCTION
1.5 PRECAST CONCRETE SYSTEM
Precast concrete is a form of concrete that is prepared, cast and cured off-site, usually in a controlled factory environment, using reusable moulds. Later then will be
transported and to set on site. In this method, building elements will be pre-made on controlled environment and will be assembled on construction site. Precast concrete
elements can be joined to other elements to form a complete structure. It is typically used for structural components such as; wall panels, beams, columns, floors, staircases,
pipes, tunnels, and so on.
1.5.1 Types of precast concrete system:
Our apartment building implement the precast system as the proposed IBS system.
Large panel system
This system is based on the use of large prefabricated components.
The components such as precast concrete large panel for walls,
floors, roofs, balconies, staircase, etc. The casting of the
components could be at the site or off the site.
Frame system
Precast frames can be constructed using either linear elements or
spatial beam-column sub-assemblages. To aid the shear transfer from
the beam to the column. The joints accomplished in this way are
hinged. However, rigid beam-column connections are used in some
cases, when the continuity of longitudinal reinforcement through the
beam-column joint need to be ensured.
Slab-column system with walls
These system rely on shear walls to sustain lateral load effects, whereas the slab-column structure resists mainly gravity loads. The slab panels are lifted to the
top of the column and then moved downwards to the final position. Temporary supports are used to keep the slabs in the position until the connection with
columns has been achieved. Most buildings of this type have some kind of lateral load-resisting elements, mainly consisting f cast-in-place or precast shear
walls.
Components of precast concrete system:
1. Precast slab
2. Precast beam
3. Precast wall
4. Precast column
5. Precast foundation
6. Precast staircase
Figure 1.7 Slab-column System with
Wall.
Figure 1.8 Frame System.
Figure 1.9 Large Panel System.
Figure 1.10 Components of Precast Concrete System.
8

Advantages
1. Saves Construction Time
Precast Concrete construction saves time, the risk of project delay is also less. The
precast concrete casting can be carried on simultaneously with other works on site
such as earthwork, survey etc. and thus saves time.
2. Quality Assurance
The key factors which regulate the quality of construction such as curing,
temperature, mix design, formwork etc. can be monitored for Precast Concrete. So,
improved quality construction can be performed.
3. Usage of Prestressed Concrete
By using pre-stressed precast, structural materials of high strength and load-bearing
capacity can be achieved, which can result in greater clear span, reduced size of cross
section of structural members etc.
4. Cost-effective:
The simplified construction process reduces the time, increases the productivity,
quality and safety and thus the cost is reduced.
5. Durability
Precast Concrete structure has longer service time period and minimal maintenance.
The high-density Precast Concrete is more durable to acid attack, corrosion, impact,
reduces surface voids and resists accumulation of dust.
6. Aesthetics
As the structures are prefabricated in a controlled factory environment, several
combinations of colors and textures can be used. A wide range of shapes and sizes are
available to choose from with smooth finishing and thus the aesthetical value of
products are increased.
7. Safe Construction Platform
No raw materials have to be stocked in site for Precast Concrete construction. It
reduces the requirement of traditional formworks and props, wastage, workers etc.
and thus provides a safe working platform.
Disadvantages
1. High Initial Investment
For installing a Precast Concrete plant, heavy and sophisticated
machines are necessary which requires high initial investment. A large
scale of precast construction projects must be available to ensure
sufficient profit.
2. Transportation Issue
The construction site can be at a distant location from the Precast
Concrete plant. In that case, the precast members must be carried to
the site using trailers. In many cases, the reduced costs of Precast
Concrete is compensated by the transportation cost.
3. Handling Difficulties
Proper care and precaution have to be taken for handling precast
concrete. Usually, precast members are heavy and large which makes it
difficult to handle without damage. Generally, portable or tower cranes
are used to handle the precast members.
4. Modification
Limitation In case of precast structures, it is difficult to modify the
structure. For example, if a structural wall is to be dismantled for
modification it will impact the overall stability of the structure.
5. Sensitive Connection Works
Assembling of the precast members is one of the key points for
ensuring strong structural behavior. Connections between several
structural members must be supervised and done properly to ensure
the intended behavior of the connection such as simple, semi-rigid or
rigid connections. Besides this, faulty connections may lead to water
leakage and fail sound insulation.
1.5.2 ADVANTAGES & DISADVANTAGES OF PRECAST CONCRETE SYSTEM
The form of construction where concrete is casted in a reusable mould and then cured in a controlled environment (precast plant) is called precast concrete. The casted structural
member is then transported to the construction site and then erected. Structural members such as concrete frame, concrete wall and concrete floors etc. can be constructed using
precast concrete.
1.0 INTRODUCTION
1.5 PRECAST CONCRETE SYSTEM
9

1.0 INTRODUCTION
1.6 CASE STUDY ON IBS SYSTEM (PRECAST CONCRETE)
Hospital Kuala Lumpur Car Park
Location: Jalan Pahang, 50586 Kuala lumpur, Wilayah Persekutuan
Kuala lumpur.
Construction period: 30 Oktober 2014 - 29 Oktober 2015
This project is in charge by Teraju Construction Sdn. Bhd (TCSB), which
is one of the leading installers of concrete products in Industrialized
Building System (IBS) industry. As its growing due to the government
requirement of 70% of IBS components must be used in government
projects which cost more than RM10 million. It is to achieve the
effectiveness in building industry sector.
The reason of building this seven-level car park is to solve the problem
of insufficient parking slot in this hospital. It is proposed to
accommodate 4080 vehicles, a cafe on ground ﬂoor and a tennis court
on the rooftop. With these facilities it provide a comfortable space for
the users with sufficient parking slots and leisure environment.
Figure 1.11 Hospital Kuala Lumpur.
10

1.0 INTRODUCTION
1.6 CASE STUDY ON IBS SYSTEM (PRECAST CONCRETE)
1.6.1 Elements used in Hospital Kuala Lumpur Car Park
Precast beam: Main Beam, Edge Beam
Function to carry external parapet wall on site and carry most of the load transfer from the slab. Dimension of both beam used in this building is 600mm width x 600mm height.
Precast column:
Precast dimension is manufactured at factory to enable fast erection by pre-customize the size and dimension and even quality control that would be hardly done at site. Basic
dimension of column in this building is 600mm x 600mm according to MS 1064: PART 10.
Precast slab: Hollow Core Slab (HCS)
It as the main components of Hospital Kuala Lumpur Car park ﬂoor slab. These slab piece by piece and with several core inside. The function of core is to reduced the weight of the
slab and giving potential to use it as a pipeline. HCS is produced and manufactured by the factory and transfer to the site.
The whole construction goes smooth and fast because of installing these kind of precast components. Hospital Kuala lumpur Car park only took one year duration to complete.
Also, the whole process is fast and required less worker.
Figure 1.12 Kuala Lumpur Hospital Car Park. Figure 1.13 Car Park Slab and Beam. Figure 1.14 Exterior of Kuala Lumpur Hospital Car Park.
11

2.1 PROPOSED IBS SYSTEM
The proposed IBS system to be suggested to the designed of this apartment blocks contain of a combination of precast concrete system and steel framing
system. Hence, it is considered the open system which allows the use of combined IBS components from different manufacturers.
Figure 2.1 Prefabricated steel roof truss.
Figure 2.2 Precast hollow core slab, columns and
beam.
Figure 2.3 Precast staircase.
Figure 2.4 Precast walls.
Figure 2.5 Prefabricated
bathroom pod.
12

2.2 PRECAST SLAB
Precast slab are made in factories and the scale are more precise and efficient and
cost friendly . It produce floor panels and roof deck panels .
Solid Flat Slab
It is a 2 way reinforced concrete slab that usually does not have beams and girders,
and the loads are transferred directly to the supporting concrete columns.
Columns tends to punch through the flat slab, it can be treated by 3 method:
1. Flat slab with drop panel
2. Flat slab with column head
3. Flat slab with column head and drop panel
Hollow Core Slab
It is a voided slab , It is a form of precast slab of prestressed concrete typicalliy
used in the construction floor of multistorey apartment buildings. The voids
reduce the weight and cost and able to hide the electrical or mechanical runs.
Single Tee
A load bearing structure that resemble one T beam connected to slab
Double Tee Slab
It is a 2 symmetrically placed beams interacting with a slab forming in one section
with a ‘double tee’ shapes made in precast , prestressed concrete. It resistance to
moisture and corrosion. Normally used in parking garage , office buildings,
commercial building and factories. When there is precast wall, precast beams,
poured concrete beams, wall , masonry walls, insulated concrete forming walls and
structural steel beam are suitable for double tee slabs as load bearing system.
Suitability of Proposed System in Building:
Component used in building: Hollow Core Slab
Advantage
- Form work is simple and less cost
- Quicker construction
- Reduce weight of the slab
Disadvantage
- Higher cost of material
Construction Method :Precast Concrete System
Construction Materials : Reinforced Concrete
Reason
- Precast slab faster construction process.
- High quality precast concrete
Figure 2.6 Types of Precast Slab.
13

2.3 PRECAST COLUMN & BEAM
Column is a structure that sustain the load from slab to beam . In IBS they given
different size and shapes and finishes. It can be square or circular and were designed to
corporate any additional features fittings. Single storey of the column will be 2.5m to
5m height. Beams are placed on top of column with dowelled connection between them.
Multi-storey columns are cast with corbels oe alternative connections at locations to
suit the beams at intermediate levels.
There 3 main types of columns.:
1. Edge column - symmetrical in one direction.
2. Internal columns- symmetrical in all directions.
3. Corner columns - not symmetrical at all.
Suitability of Proposed System in Building
Component used in building: Single storey Corbel Column
Reason:
- Structural Stable
- Corbel allowed the column to sustain structural load
- Weight will transfer from corbes down into core column
-
Beams is a horizontal member that were built to transfer load from wall or slab
above and transfer the same to vertical support. It is commonly used to support a
long span hollow core slab because it provide enough bearing seating for the slab.
It is also used as ledges for other forms of precast flooring to sit on and are
generally manufactured to suit each situation.
There 2 main categories of beam:
1. Internal beams - Where floor loading is approximately symmetrical
2. External beams- Where floor loading is predominantly non-symmetrical
.
Internal
Beam
External
Beam
2.2.1 Precast Column
2.2.2 Precast Beam
Figure 2.7
Figure 2.8 Internal Beam.
Figure 2.9 External Beam.
Figure 2.10 Single and Multi Storey Column.
Figure 2.11 Types of Beam Installation.
14

2.3 PRECAST COLUMN & BEAM
2.2.3 Type of Beam
Inverted Tee Beam
Generally used for flooring system and being infill where there has
provided a ledger for precast floor unit to sit on.
Rectangular Beam
Generally used to span clear sections and are reinforced or prestressed
L- Shape Beam
It provides a ledge for a precast flooring system to sit on. It is generally used to
span clear sections and are reinforced and prestressed.
Component used in building: L- shape Beam and Inverted Tee Beam
Reason:
- Easy to assemble hence faster construction process.
Figure 2.12 Types of Beams.
15

2.4 PRECAST CONCRETE WALL
It serve 2 functions which are stability and as well as wall or boxes surrounding
staircases and lift shafts.
Walls can be classified as infill or cantilever.
- Infill walls are strong dependent on the adjacent composite action follow
with the beam and column frame.
- Cantilever walls or boxes are act as beams which the frame is attached.
Shear walls
- It provide lateral load resisting system when it is combine with diaphragm
action of the floor construction.
- It depending on the panel- to - panel connection
Formwork for cast-in-place concrete
- Cast in place concrete use precast panel as formwork.
4 types of precast panels used as part of building envelopes:
Cladding or Curtain walls
- It does not transfer vertical load but enclose the space.
- Designed to resist wind and sustain it own weight and as well as force
are transfer to the supported panel.
- It include wall panels, window wall units, spandrels, mullions , and
column covers. These units are able to remove individually if necessary.
Load-Bearing Wall Unit
- It resist and transfer load from other component
- If it has been removed it will affect the strength and stability of the
building.
- It include solid wall panels, and window wall and spandrel panels.
Figure 2.14 Cladding or
curtain walls.
Figure 2.15 Load- Bearing Wall units. Figure 2.16 Shear Walls.
Component used in building: Cladding or curtain wall
Reason:
- Aesthetically pleasing
- Minimal maintenance Needed
- Save space on site
Figure 2.13 Attaching wall act as beam.
16

2.5 PRECAST CONCRETE STAIRCASE
Precast concrete staircase can speed up the site production compare to cast
in-situ concrete.
Precast stairs are suitable to the construction of high traffic stairwells for example
industrial and commercial developments. Besides that, the ﬁnishes of precast
concrete staircase make it more durable and for long maintenance free life.
Concrete stairs are preferable for high quality private and residential stairway. The
stairs gives an excellent acoustic properties as it is denser compare with steel and
wooden staircases. Besides that, it offers rapid installation and early safe access
to the subsequent ﬂoors for trades and materials.
Advantages :
- Durable
- Excellent acoustic properties
- Maintenance-free
- Rapid installation
Disadvantages :
- Transporting difficulties
- Repairing damage.It is hard to repair precast concrete steps. There are
hardly any structural elements within the concrete.
- Railing attachment. Railings should be able to support 200 Ibs, however,
precast staircase cannot sufficiently be supported by lateral pressure.
Component used in building: Scissors staircase
Reasons:
- Contemporary design to suit the whole apartment design
- More economical to cut costs of construction
Storey Height
(mm)
Riser (mm) Thread (mm)
2800 175 250
3000 167 250
3500 175 250
Figure 2.17 The preferred sizes of staircase according to MS 1064.
Figure 2.18 Vertical coordinating sizes of scissors stairs according to MS 1064.
Figure 2.19 Precast Concrete Stairs.
17

2.6 PREFABRICATED BATHROOM POD
Construction Method :Prefabricated bathroom pod
Bathroom pod is a prefabricated bathroom and is delivered ready for installation. It
is installed with the use of “Plug and Play” concept that is meant for fast paced
construction industry. It consists of rooftop panel, plumbing and electrical
component, interior walls, waterproof wall board and also floor tiles. The plumbing
and electrical components are integrated so it is ready for final hookup. The
interior walls are completely finished and clean. Besides that, the waterproof wall
board is moisture-resistant wallboard that is glued and screwed to the framing.
Last but not least the floor tiles are waterproof too. It has a thin profile subfloor
which supports floor finish and providing a seamless transition to the adjoining
floor.
Advantages :
- Quality control. Bathroom pods is more effective at delivering higher quality
and more profitable outcomes compare with the traditional on-site builds,
- Time saving. By using prefabricated toilet pods, the units can be very
quickly connected into the building with lower level of skills required.
- Sustainability. It is less wasteful to use prefabricated bathroom pods than
the traditional forms of construction.
-
Disadvantages :
- Transporting difficulties
Component used in building: Prefabricated modular bathroom pod
Reasons:
- High quality of construction
- More economical
- Saving construction costs
Plumbing and Electrical
Rooftop Panel
Interior WallWaterproof Wall
Board
Floor Tiles
Figure 2.20 Prefabricated bathroom pod. Figure 2.21 Advantages of using prefabricated bathroom pod.
18

2.7 PREFABRICATED STEELROOF
Construction Method : Prefabricated lightweight steel system
Construction Materials : Steel (King post roof truss)
Truss is a triangle or arch shape frame used a majority in roof cover it. It is a
structure with straight pieces forming triangles. The function of it is to support
load. Although the members of triangles are placed under tension however it does
not bend.
The truss used in this building is King Post roof truss. The bottom chord of the
truss acts as a tie beam and the tie beam receives the end of the principle rafters.
This is to prevent the walls from spreading out due to thrust.To prevent the sagging
of tie beam at the centre of a span, vertical king post is used.The function of
structs are to prevent sagging of principle rafters. Ridge beam is to provide
support of common rafters. Besides that, the trusses are supported on concrete
which are fixed in the supporting walls.
The steel trusses are prefabricated. It is then transported to the site and lifted by a
crane. It is then aligned into position and bolted in place. It is secured onto the
building by anchor bolts and welded. Lastly, C-channel purlins are welded onto the
rafters.
Advantages :
- Lightweight
- Fire resistance. A coat of fire-retardant coatings caused the steel roof
truss indestructible by fire.
- Heat conduction. Steel is emissive, it emits any heat that is absorbed.
- Fast installation of roof.
- Durable. A steel roof can last as long as the house.
Disadvantages :
- Noise disturbance. It can be very disturbing staying under thin sheets of
metal compare to tiles, especially during a rainstorm or hailstorm.
- High cost. Cost of steel roof is as expensive as other premium materials
Component used in building: King Post Roof Truss
Reasons:
- Reduce structural weight as application of pad footings supports limited
amount of weight.
- Easy to install, hence it will reduce construction time of our apartment
Common Rafter
Principal Rafter
Supporting wall
Tie Beam
Stone Template
King Post
Strut
Ridge Board
Purlin
Figure 2.22 King post roof truss. Figure 2.23 Prefabricated lightweight steel roof.
19

3.0 TECHNICAL DRAWINGS
3.1 ARCHITECTURE DRAWINGS (SCALE 1:100)

3.1.1 LEVEL 1-3 PLAN
A A’
B’
B
21

3.2 STRUCTURAL DRAWINGS (SCALE 1:100)

3.2.1 LEVEL 1 - 2 STRUCTURAL PLAN 30

3.2.2 LEVEL 3 STRUCTURAL PLAN 31

3.2.4 LEVEL 1-3 FLOOR SLABS STRUCTURAL PLAN 33

3.3 3D MODEL DRAWINGS (N.T.S.)

3.3.2 ROOF EXPLODED AXONOMETRIC
Roof Beam
Roof Truss
Purlin
Rooﬁng
36

3.3.3 SECTIONAL A-A’ PERSPECTIVE 37

3.3.4 SECTIONAL B-B’ PERSPECTIVE 38

4.1 PREFABRICATED LIGHTWEIGHT STEEL ROOF
39

4.1 PREFABRICATED LIGHTWEIGHT STEEL ROOF
40

4.2 PREFABRICATED WINDOWS
41

4.3 PRECAST HOLLOW CORE CONCRETE SLABS
42

4.3 PRECAST HOLLOW CORE CONCRETE SLABS
43

-
4.4 PRECAST CONCRETE COLUMNS
44

-
4.4 PRECAST CONCRETE COLUMNS
45

-
4.5 PREFABRICATED DOORS
46

4.5 PRECAST CONCRETE STAIRCASE
47

The preparation and construction of
in-situ foundation, ground beam and
ground ﬂoor slabs . Reinforce
concrete stump and starter bars
ready to connect with precast
columns.
Put up precast concrete columns and
beams into position. All precast
component must be popped during in
installation.
Installation of precast concrete half
slabs. All precast slabs must be
popped during installation.
Casting of concrete topping in single
operation.
Precast columns must be popped in 2
direction for proper alignment
Precast beams to be propped and
adjusted to correct level
Placing of top reinforcements for
beam
Placing of top reinforcements for
slabs
1
2
3
4
Figure 5.1 Foundation.
Figure 5.3 Installation of precast column and beam.
Figure 5.5 Installation of precast slab.
Figure 5.7 Casting of concrete topping.
Figure 5.2 Detailing of column installation.
Figure 5.4 Precast beam installation detail.
Figure 5.6 Reinforcement of beam.
Figure 5.8 Reinforcements of slab.
5.1 CONSTRUCTION SEQUENCE OF SLAB, BEAM AND COLUMN
48

5.2.1 Column to Footing
5.2.2 Column to Column
The column and column stumps are assemble on site. The base plate are
being welded on to the bottom of column. The column and footing are
connected by bolting connections.
This connection may be considered in design as monolithic providing the
bedding joint and grout sleeves are completely filled with grout to the
satisfaction of the site engineer.
At the end of the column, there will have metal plates and embedded
anchor bolt are cast on it. The column are mechanically joined together.
After it is connected the entire joint is dry-packed with grouted to
provide full bearing between element and protect the metal from fire and
corrosion.
5.2 CONNECTION DETAILING OF SLAB, BEAM AND COLUMN
Figure 5.9 Before Assembled. Figure 5.10 Assembled. Figure 5.11 Grouted.
Figure 5.12 Connecting by metal
plates and anchor bolts.
Figure 5.13 Column fix to the
place.
Figure 5.14 Final cast in
concrete.
49

5.2.3 Beam to Column
Figure 5.16 Weld plates (PCI Design Manual
on Connections).
50
Corbels are mainly used to resist hogging moments by providing ﬁxity to
the column near to, or at the top of the beam. This may be in the form of
bolts into cast-in sockets, welded bars or plates, or a grouted lap joint.
Metal Plate Cast
Bearing Pad
Beam are being placed on top of bearing pads and on top of the column
corbels steel angle are being welded to metal plates and cast into the
beams and column and the joint is grouted solid.
Figure 5.15 Connection with steel billet
connector.
Connections with projecting bars in grouted ducts.
Wall
element
Project
ing bar
Grouted
sleeve
Wall
element Anchor bar
Grouted
sleeve
Wall
element
Project
ing bar
Mortar
joint
Socket
Anchor
bar
Bearin
g strip
Tie bar
Figure 5.17 Load transfer mechanism through beam end
to column connection.
This connection is used mainly in portal frames, it may be used in skeletal
frames where continuous (or cantilevered) beams are required.
The column head connection may be designed with, or without
contributions from ﬂoor slabs and tie steel.
Figure 5.18 Continuous cantilever beams at column head.

51
5.2.4 Slab to Beam & Slab to Slab
Hollow core slab is being supported by L beam . The anchored tie bar in
hollow core floor.
The tie bars have to be grouted in suitable positions of the precast floor
slab ( hollow-core slabs) or in the structural topping, when topping is
specified. The tie bar has to be positioned as low as possible in the
transversal section at the support in order to avoid unintended restraint
and to permit free rotation of the slab end under the superimposed load
according to the simple bearing scheme.
EDGE SUPPORT
INTERNAL SUPPORT
Figure 5.20 Connection of slab to beam.
Figure 5.22 Connection of slab to slab.
Figure 5.19 Unintended wall restraint for
exterior support.
Figure 5.21 Unintended wall restraint for
interior support.

Precast Concrete Staircase Construction Sequence
5.3 CONSTRUCTION SEQUENCE OF PRECAST CONCRETE STAIRCASE
Crafting Template
Using a designated template (installation
producing crane, finishing platforms),
mount pad in the design position. Then,
trowel to put on the receiving space
platform cement-sand mortar. Then
position landing and verify soffit level at
four corners. Adjust level to within
tolerance.
During construction
The first flight of stairs have it down and
then lower the top. The mounting crowbars
can be improve by not hooking march.
Then, lay and unhook the march zamonolitit
mounting clearances cement sand mortar.
Finishing
Repeating the same construction process
for the continous floors. Railings are then
installed after the flight of steps are
completed.
Template
Cement-Sand-Mortar
1 2 3
52
Figure 5.23 Creating Template. Figure 5.24 Constructing. Figure 5.25 Finishing.

Landing Slab
Precast Staircase to landing slab connection
Precast Staircase to ground ﬂoor slab connection
53
5.4 CONNECTION DETAILS OF PRECAST CONCRETE STAIRCASE
Figure 5.26 Precast concrete staircase

5.4 CONNECTION DETAILS OF PRECAST CONCRETE STAIRCASE
A
B
C
D
A
B
C
D
A
B
C
D
C
B
A
A. Slab
B. Precast Staircase
C. Sleeve
D. Non shrink grout
A. Precast Staircase
B. Plate
C. Bent Plate
D. Precast Landing
A. Precast Landing
B. Precast Wall
C. Plate
D. Structural Shim Packer
A. Precast Staircase
B. Plate
C. Precast Landing
5.4.1 Stair to Floor Connection 5.4.2 Landing to Down Riser Connection
5.4.3 Landing to Wall Connection 5.4.4 Landing to Up Riser Connection
54
Figure 5.27 Stair to ﬂoor connection
Figure 5.28 Landing to down riserr connection
Figure 5.30 Landing to up riserr connectionFigure 5.29 Landing to wall connection

55
Apex Joint
Web Joint
Web Joint
Heel Joint
5.5 KING POST ROOF TRUSS JOINT CONNECTION
Top Chord (Rafter)
Apex is known as the peak. It is the
highest point on a truss where the
sloping top chords meet.
Web is a member that combines the
top and bottom chords of a truss, to
form a triangular pattern. Webs may
carry tensile or compressive forces,
depending on their position in the
truss.
The heel of the roof truss is the point
of the truss ay which the top chord
(rafter) and bottom chord intersect.
55
A chord is one of the main members that
form the outline of the truss. They are
subject to relatively large axial forces as
well as bending moments. Besides that, a
joint is an intersection point of one or
more webs with a chord.
Figure 5.32 Apex Joint.
Figure 5.31 King Post Roof Truss.
Figure 5.33 Web Joint.
Figure 5.34 Web Joint 2.
Figure 5.35 Heal Joint.

56
Rafter
Bolts
Rafter
King Post
Tie Beam
Top View
Top View
Bolts
Top View
5.6 CONNECTION DETAILS OF KING POST ROOF TRUSS
Built up/composite
cladding
Rafter Stay
Column Stay
Figure 5.36 Details of King Post Roof Truss.
Figure 5.37 Roof Truss Connection
Figure 5.38 Roof Truss Connection

57
5.7 CONSTRUCTION SEQUENCE OF PREFABRICATED BATHROOM POD (INSTALLATION WITH ROLLERS)
1 2 3 4
5 6 7
The finished pods are
transported by truck to the
construction site. They are
wrapped in heat shrink wrap for
protection purposes.
The pods are unloaded with a
crane or forklift truck. It will be
positioned onto special rollers in
order to be rolled into its final
position.
Rollers are placed on the platform
and the pod will be slowly
positioned on them by the crane
It is important that the route is smooth, leveled and free
from any openings such as ducting shafts, so the rollers
can run freely along the surface.
For low inter storey height, special rollers will
be applied to the sides of the pod’s structure
instead of under the base.
Besides that, smaller pods can be rolled to
their final position just with an electric pallet
truck with forks long enough to reach the back
wall to avoid distortions and damage to its
base.
Last but not least, the rollers are
released by means of standard
hydraulic jacks. The surface under
the pod is checked if it’s in perfectly
level to avoid any distortion.

6.0 IBS SCORE CALCULATION
Say, from measurement taken from drawings:
1) Construction area
i) Construction area level 1 =203.5 m2 (1 Unit= 101.75 m2)
ii) Construction area level 2 = 203.5 m2 (1 Unit= 101.75 m2)
iii) Construction area level 3 = 203.5 m2 (1 Unit= 101.75 m2)
iv) Construction roof area = 349.00 m2
v) Staircase corridor area = 39.00m2
Total construction area= 998.5 m2
2) Structural Systems
i) Beams: Precast concrete beams
ii) Columns :Precast concrete columns
iii) Floor slab:Precast concrete hollow core slabs
iv) Roof truss: Prefabricated metal roof truss
3) Wall System
i) Internal wall: Precast concrete walls
ii) External wall: Precast concrete walls
4) Other simpliﬁed construction solutions
i) Door = Prefabricated door
ii) Window = Prefabricated window
Formula:
1) Score for structural system =
2) Score for wall system =
3) Total IBS score =
58

ELEMENTS
AREA (m2 ) or Length
(m)
IBS FACTOR COVERAGE IBS SCORE
PART 1:Structure Elements
Precast Concrete Beam and Column +
Precast Concrete Slabs
Total area = 242.5 m2 x 3 storeys
= 727.5 m2
727.5 m2 1.0 (727.5/1076.5)
= 0.68
0.68 x 1.0 x 50
= 34
Roof truss using prefabricated steel Roof
area
= 349 m2
349 m2 1.0 (349/1076.5)
= 0.32
0.32 x 1.0 x 50
= 16
Total Part 1 1076.5 m2 1.0 50
PART 2: Wall System
External and Internal Wall using Precast
Concrete Panel Wall
192,900 1.0 (192,900/192,900)
= 1.0
1.0 x 1.0 x 20
=20
Total Part 2 192,900 1.0 20
Part 3: Other simplified construction solutions
i) 50% of door sizes follow MS 1064 Part 4 50% 2
ii) 100% of window sizes follow MS 1064
Part 5
100% 4
iii) Repetition of floor to floor height = 33% 33% 2
iv) Vertical repetition of structure = 100% 100% 2
v) Usage of modular grid lines = 42% 42% 4
Total Part 3 14
Total IBS Score (Part 1 + Part 2 + Part 3) 84 Points
6.0 IBS SCORE CALCULATION
59

7.0 CONCLUSION
This project has acknowledge us to have deeper understanding towards of precast concrete IBS system and prefabricated lightweight steel system, which all components
are manufactured in an controlled environment. In addition, the construction process of model making gave us a grasp on-site assembling of the model which resembles to
the actual site construction. They also allowed us to have a better understanding of how each component are assemble together.
Therefore, IBS score is calculated to allowed us to identify weather the apartment has fulﬁls the IBS score benchmark. with an IBS score of 84/100 3-storey apartment. It
implies that a clear understanding of components that are manufactured in an controlled environment have applied to the design of 3-storey apartment. The IBS applied
include precast hollow core slab, singular corbel column, ‘L’ shaped beam and Inverted tee beam, cladding curtain wall, scissors staircase, prefabricated modular bathroom
pod and prefabricated steel trusses, has contribute to the IBS score.
In conclusion, IBS is a system that are beneﬁcial to enhance construction sustainability, it reduces cost, reduces construction time , total cost and less workers needed. It
also increases the quality of the building. It gave a safer and systematic factory working environment and a cleaner site. Thus, it is an encouragement to used IBS system,
to have a better environment, consistency of quality work and effective constructions.
60

8.0 REFERENCES
Topic 1:Introduction
1. Essays, UK. (November 2018). The Definition Of Industrialised Building System
Construction Essay.
Retrieved from
https://www.ukessays.com/essays/construction/the-definition-of-industrialised
-building-system-construction-essay.php?vref=1
2. Advantages and Disadvantages of Precast Concrete Construction. (2011).
Retrieved from
https://cw2011workshop05.wordpress.com/2011/09/22/advantages-and-disadvan
tages-of-precast-concrete-construction/
3. PRECAST BUILDING SYSTEM. (2016). Presentation.
4. Precast concrete - Designing Buildings Wiki. (2019). Retrieved from
https://www.designingbuildings.co.uk/wiki/Precast_concrete
5.Agarwal, K. (2014). Prefabrication. Lecture.
6. Precast Concrete. (2016). Presentation.
7. Mahdi, S. Advantages and Disadvantages of Precast Concrete - Civil Engineering.
Retrieved from
https://civiltoday.com/civil-engineering-materials/concrete/232-advantages-and
-disadvantages-of-precast-concrete
8. IBS Seminar Notes Yeap 1.0 - QS Perspective on HKL SCACC 10Dec13. (n.d.).
Retrieved from
https://www.scribd.com/document/191993300/IBS-Seminar-Notes-Yeap-1-0-QS-
Perspective-on-HKL-SCACC-10Dec13
9. THE BEST CHOICE IN MAINTENANCE SOLUTION. (n.d.).
Retrieved from http://www.fabuloustrack.com.my/
Topic 2: Concept And Framework
1.Google.com. (2019). type of precast slab ibs - Google Search. [online]
Available at:
https://www.google.com/search?q=type+of+precast+slab+ibs&tbm=isch&source
=univ&sa=X&ved=2ahUKEwivn8OY4YDiAhWD6XMBHZVXCfIQsAR6BAgJEAE&biw=
2048&bih=963#imgrc=EcvJ1z_gi3RtiM: [Accessed 15 May 2019].
2.Alfanarprecast.com. (2019). alfanar precast. [online]
Available at:http://alfanarprecast.com/tee_slabs.html [Accessed 15 May 2019].
3.Scribd. (2019). Project 1 : Industrialized Building System | Precast Concrete | Beam
(Structure). [online]
Available at:
https://www.scribd.com/document/367790101/Project-1-Industrialized-Building-
System [Accessed 15 May 2019].
4. Developed and Managed by Netconstruct - www.netconstruct.co.uk - 44 (0)1937
581 123. (n.d.). Concrete Stairs.
Retrieved May 15, 2019, from
http://www.acp-concrete.co.uk/precast-concrete-products/floors-and-stairs/co
ncrete-stairs/
5. Mewada, A. (2015, August 20). PRECAST CONCRETE STAIRS.
https://www.slideshare.net/abhishekmewada54/precast-concrete-stairs
6. The Disadvantages of Precast Concrete Stairs. (n.d.).
https://www.hunker.com/13403139/the-disadvantages-of-precast-concrete-stair
s
7. Bathroom Pods. (n.d.).
https://www.modularadvisor.com/product/bathroom-pods/
8. Plug and Play | SurePods Prefab Bathrooms. (2018, February 12).
Retrieved May 15, 2019, from https://oldcastlesurepods.com/blog/plug-and-play/
61

8.0 REFERENCES
9. Gharpedia.comGharpedia.com helps to
Build/Own/Rent/Buy/Sell/Repair/Maintain your dream house by providing all the
tips & tricks in easy languages. It provides solutions to all problems pertaining to
houses right from concept to completion. (2019, February 11). King Post Truss: All
You Need to Know. Retrieved May 15, 2019, from
https://gharpedia.com/king-post-truss/
10. Team, W. (n.d.). The Lowdown on Building with Steel Roof Trusses. Retrieved
May 15, 2019, from
https://www.whirlwindsteel.com/blog/bid/407704/the-lowdown-on-building-with
-steel-roof-trusses
11.Alfanarprecast.com. (2019). alfanar precast. [online] Available at:
http://alfanarprecast.com/tee_slabs.html [Accessed 15 May 2019].
12.Google.com. (2019). type of precast slab ibs - Google Search. [online] Available at:
https://www.google.com/search?q=type+of+precast+slab+ibs&tbm=isch&source
=univ&sa=X&ved=2ahUKEwivn8OY4YDiAhWD6XMBHZVXCfIQsAR6BAgJEAE&biw=
2048&bih=963#imgrc=EcvJ1z_gi3RtiM: [Accessed 15 May 2019].
13.KUMAR (2019). Prefabricated wall panel. [online] Slideshare.net. Available at:
https://www.slideshare.net/SAHILKUMAR157/prefabricated-wall-panel [Accessed
15 May 2019].
14.The Constructor. (2019). Types of Precast Components in a Building. [online]
Available at:
https://theconstructor.org/concrete/types-of-precast-components-in-a-building
/6325/ [Accessed 15 May 2019].
15.User, S. (2019). L-Shape. [online] Humeconcrete.com.my. Available at:
http://humeconcrete.com.my/index.php/features/bagged-2/reinforced-concrete
-square-pile-2 [Accessed 15 May 2019].
17.Encrypted-tbn0.gstatic.com. (2019). [online] Available at: 16. Scielo.br. (2019).
[online] Available at: http://www.scielo.br/img/revistas/lajss/v8n4/a02fig01.jpg
[Accessed 15 May 2019].
https://encrypted-tbn0.gstatic.com/images?q=tbn:ANd9GcSN7MhfIdvgmzgQ2IZG
edatjcHQBH4XyXHU_1TGjP7_Pgus8fpP [Accessed 15 May 2019].
18. The Constructor. (2019). Types of Precast Components in a Building. [online]
Available at:
https://theconstructor.org/concrete/types-of-precast-components-in-a-building
/6325/ [Accessed 15 May 2019].
19.Frontdesk.co.in. (2019). [online] Available at:
http://frontdesk.co.in/big/cm/beams.jpg [Accessed 15 May 2019].
20.Wells Concrete. (2019). The Benefits of a Precast Wall Panel System - Wells
Concrete. [online] Available at:
https://www.wellsconcrete.com/blog/benefits-precast-wall-panel-system/
21. Front Desk Architects. (2019). Precast Construction - Front Desk Architects.
[online] Available at:
http://frontdesk.co.in/construction-materials/precast-construction/ [Accessed
15 May 2019].
62

8.0 REFERENCES
Topic 6:IBS Score Calculation
1. Department of Standard Malaysia (2003). Guide to Modular Coordination in
Buildings: Part 5: Coordinating Sizes And Preferred Sizes for Window Sets.
Cyberjaya: Department of Standards Malaysia .
Buildings: Part 4: Coordinating Sizes And Preferred Sizes for Doorsets. Cyberjaya:
Department of Standards Malaysia .
Buildings: Part 10: Coordinating sizes for reinforced concrete components..
Cyberjaya: Department of Standards Malaysia .
4. Department of Standards Malaysia. Malaysian Standard: Guide to Modular
Coordination in Buildings (MS 1064: 2017). Department of Standards Malaysia; 2017.
5. Construction Industry Development Board. Construction Industry Standard:
Manual for IBS Content Scoring System (IBS Score) (CIS 18: 2010). Kuala Lumpur:
CIDB; 2014.
Topic 5: Construction Details
1..Cms.simplewebdiy.com. (2019). [online] Available at:
http://cms.simplewebdiy.com/upload/company/29/images/ibs2-3a_57.jpg
2.Uct.ac.za. (2019). [online] Available at:
http://www.uct.ac.za/sites/default/files/image_tool/images/333/Events/PP_201
3_3_Precast_Concrete_SA.pdf [Accessed 15 May 2019].
3. Developed and Managed by Netconstruct - www.netconstruct.co.uk - 44 (0)1937
581 123. (n.d.). Concrete Stairs. Retrieved May 16, 2019, from
http://www.acp-concrete.co.uk/precast-concrete-products/floors-and-stairs/co
ncrete-stairs/
4. Roof Trusses Manufacturers Terminology – Components of a Truss. (n.d.).
https://endotruss.co.za/roof-trusses-manufacturers-terminology-components-o
f-a-truss/
5. Bathroom Pods Installation. (2017, January 09). Retrieved May 16, 2019, from
https://www.cellulebagno.com/en/bathroom-pods-installation
6.Scribd. (2019). Project 1 : Industrialized Building System | Precast Concrete | Beam
(Structure). [online] Available at:
https://www.scribd.com/document/367790101/Project-1-Industrialized-Building-
System [Accessed 16 May 2019].
7. fib Bulletin 43: Structural connections for precast concrete buildings.Retrieved
May 16, 2019, from https://doi.org/10.3897/BDJ.4.e7720. (n.d.).
doi:10.3897/bdj.4.e7720.figure2f
63

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