This document provides information about precast concrete panel systems used in construction. It begins with an introduction to Industrialized Building Systems (IBS) and defines precast concrete panel systems. It then discusses the manufacturing process for precast concrete panels and provides photos of each step. Advantages and disadvantages of precast concrete panel systems are outlined. Finally, two case studies are presented that utilized precast concrete walls on projects in Senawang and Bangi.

2.
CONTENTS PAGES
1. Introduction 2 - 3
2. Manufacturing Process of the Structural Elements 4 - 8
3. Advantages & Disadvantages 9
4. Case Study 10 - 17
5. References 18
Taylor’s University | Construction Technology III | ​Precast Concrete Framing, Panel & Box System
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3.
In the era of globalization, there are actually tons of information,
knowledge, and technology that are shared and transferred easily across
the globe. Here, we have Industrialized Building System (IBS) that is still
considered new in Malaysia whereas it is already counted as an old
technology in countries that are developed.
IBS has already been implemented in Malaysia since the 60s but
only became widely known in the year 1998 when the Cabinet of
Ministers endorsed IBS Strategic Plan as the blueprint for the total
industrialisation of construction sector. But what exactly is IBS?
Well, we quote CIDB, “IBS is actually a construction system which
components are manufactured in a factory, on or off site, positioned and
assembled into structures with minimal additional site work”. IBS can also
give the definition of a construction system that is built using
pre-fabricated components.
This would bring us to the topic of our assignment that falls under
one of the main IBS groups identified in Malaysia, which is precast
concrete framing, panels and box system. This system includes precast
columns, beams, slabs, and 3D components. But due to the fact that all 3
systems have way too many information for our assignment, our group
were asked to pick just 1 system to focus on. After discussing among
ourselves, we have chosen ​precast concrete panel system as our primary
focus.
To be more detailed on what panel system is all about, it is basically
the structures that carry the weight through large floors and wall panels,
and usually consist of sandwich panel, half-slab, as well as hollow slab.
The panels could be made up of different types of forms and materials
Taylor’s University | Construction Technology III | ​Precast Concrete Framing, Panel & Box System
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4. that are normally casted in the factory. But in some occasions, it may be
fabricated on site depending on the scale of the project.
The panel system is suitable to be used in buildings that
functionally require a large number of walls such as for apartments,
hotels, hospitals, etc. It is not encouraged to be applied to buildings that
have large spans or a lot of storeys. Jointing at site is the key issue of this
system.
FIGURE 1.0
Precast Concrete Panel System
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5.
The concept of precast (also known as prefabricated) construction
includes those building, where the majority of structural components are
standardized and produces in plants in a location away from 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.
Precast Slab
Precast Wall
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6. 1. Production of reinforced cages and main connections:
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. ​Reinforcement bars are
bent and reinforcement cages prepared in the bending and
reinforcement assembly shop.
2. Assembly of moulds:
The reinforced cage is positioned in the partly assembled mould,
then the remaining mould section is completed. ​Forms can be
assembled in both production shops (small and big assembly line),
i.e. wooden fill-in and reinforcement are inserted into steel forms of
the precast concrete element to be produced.
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7. 3. Mix being poured:
Carefully specified concrete is placed into the mould. Many precast
works now employ computer controlled batching plants. ​Concrete
is placed from concrete skips handled with an overhead crane.
Concrete is produced in a concrete batching plant.
4. Compaction of concrete using poker vibrator:
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.
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8. 5. Precast concrete being moved to the storage area:
Once an appropriate strength has been reached, the precast units
are moved to the storage area. Units are usually handled within
hours of casting as part of the rapid production cycle. The product
exhibits a high degree of dimensional accuracy and quality of finish.
Economies of production are achieved through the repetitive and
automated process.
6. Storage of high-quality units of work area:
The finished precast components are stacked on clean battens or
plastic pads positioned to suit the design of the component. Care is
taken to keep the stacks vertical and to ensure that battens are
placed directly above one another within the stack.
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9. 7. Transport to site:
Large linear precast concrete elements can be transported by three
overhead cranes directly from the production shop and loaded onto
trucks. ​The components are delivered to site in a predetermined
sequence to ensure that hardened concrete are ready for instant
erection.
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10.
ADVANTAGES DISADVANTAGES
Quality can be controlled and monitored
much more easily .
Connections between panel will be
difficult.
Quantity discount can lower cost due to
precaster buy materials for multiple
projects.
Joints between panels are often
expensive and complicated.
Weather is eliminated as a factor, can
cast in any weather and still get the
same results.
Cranes are required to lift the panel. Will
also effects the expenses.
Less labour is required and that labor
can be less skilled.
Limited building design flexibility.
Repeatability - easy to make many
copies of the same precast products.
Very small margin for error.
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11.
Senawang, Negeri Sembilan
Function of Building : ​Office and Apartment
Construction Period :​ 1 year, Dec 2003-2004
Architect : ​Public Works Department, Malaysia
Consulting Engineer : ​Public Works Department, Malaysia
Manufacturer :​ Sunway Precast Industries Sdn. Bhd.
IBS system : ​Precast Concrete Walls
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12. Apart from new school buildings, the Public Works Development
has also embarked on the new design of Government quarters using IBS.
The Senawang Police Quarters is one such pilot project that employed
this new design. In this project, precast concrete wall panels that acts as
load-bearing walls and facade were utilized. This project shows that, with
design creativity and standardisation of precast components and
connections, a wide variety of designs can be achieved with precast
concrete. The repetitiveness of element and rapid construction of precast
concrete give economic advantages to the system over the conventional
cast in-situ system.
Figure 2.0​ ​Perimeter load
bearing walls function as
structural elements and facades
Figure 2.1 ​Erection of wall panel
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13.
Bangi, Selangor
Function of Building :​ Quarters for Training Institute
Construction Period :​ March 1999- August 1999
Owner :​ Judicial and Legal Training Institute
Client :​ Public Works Department (PWD)
Manufacturer :​ Norwest Holding Sdn. Bhd.
IBS system : ​Precast concrete walls and plank slabs
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14. The complex consists of four-storey and five-storey building blocks.
The building were designed based on the PWR/ JKR standard building
type, G2. In the case of the five-storey block, the first storey was built
using cast in-situ concrete beams and columns with the upper four storey
was built with precast concrete wall system. For the four-storey blocks, all
four storeys were constructed using precast slabs and walls. The precast
concrete system consists of precast concrete precast walls and planks.
The wall comprised load-bearing double walls of 170mm thick and
non-structural solid walls of 125mm thick. The floor system for the first
and fourth storeys consisted of 50mm-thick precast half slabs, combined
with 100mm-thick cast in-situ concrete to give total slab thickness of
150mm. The floor slabs sat on double walls with the specified bearing
length. The project, started in March 1999, was completed in August
1999.
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15.
Figure 3.0
Precast concrete
panel wall under
construction
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16.
Parcel 8, Precinct 9, Putrajaya.
Function of Building : ​Apartment
Construction Period : ​15 months (10 months for the erection of precast
concrete structure)
Owner :​ Putrajaya Holding Sdn. Bhd.
Architect : ​ZMD Architect.
Consulting Engineer : ​Case Consultants Sdn. Bhd.
Jentrikon Perunding Sdn. Bhd.
Contractor : ​Setia Putrajaya Sdn. Bhd.
Manufacturer : ​Setia Precast Sdn. Bhd.
IBS system : ​Precast concrete walls and plank slabs
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17. The complex consists of two apartment blocks, namely, Block A and
Block B, with 17 and 16 floors respectively. There are total of 658 units for
the two blocks, and 19,000 precast panels were used for their
construction. The rate of erection was approximately four units per day.
Cast in-situ slabs were used for floor system, and this minimised leakage,
enhanced restraint at the wall ends and produced monolithic slabs to
give good diaphragm action. No beams and columns were used in this
system.
Figure 4.0 ​View of the
construction site, clean and
systematic
Figure 4.1 ​Precast concrete panel
ready to be lifted and erected
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18.
Figure 4.2 ​Erection of concrete
wall panels is fast with just in
time delivery.
Figure 4.3 Painting on the high
quality surface of precast
concrete wall panels
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19.
1. Mishra, G. (2017). ​Precast Concrete Construction - Process and
Advantages​. ​The Constructor​. Retrieved 6 June 2017, from
https://theconstructor.org/concrete/precast-concrete-construction/2
73/
2. What is concrete? What is a precast concrete product?​. (2017).
BIBM​. Retrieved 6 June 2017, from
http://www.bibm.eu/precast-concrete/what-is-concrete--what-is-a-pr
ecast-concrete-product-
3. Precast Concrete-Panel Buildings. (2006). Industrialised Building
Systems In Malaysia.​ Malaysia: (n.p.).
4. Performance of IBS Precast Concrete Beam-Column Connections
Under Earthquake Effects: A Literature Review​. (2017).
ResearchGate​. Retrieved 6 June 2017, from
https://www.researchgate.net/publication/285050246_Performanc
e_of_IBS_Precast_Concrete_Beam-Column_Connections_Under_
Earthquake_Effects_A_Literature_Review
5. EFFECTIVENESS OF INDUSTRIALISED BUILDING SYSTEM (IBS)
IMPLEMENTATION FOR MALAYSIAN CONSTRUCTION INDUSTRY​.
(2017). ​Eprints​. Retrieved 6 June 2017, from
http://eprints.uthm.edu.my/1700/1/MARDHIAH_ZAWAWI.pdf
6. EFFECTIVENESS OF INDUSTRIALISED BUILDING SYSTEM (IBS)
IMPLEMENTATION FOR MALAYSIAN CONSTRUCTION INDUSTRY​.
(2017). ​Eprints​. Retrieved 6 June 2017, from
http://eprints.uthm.edu.my/1700/1/MARDHIAH_ZAWAWI.pdf
7. Mishra, G. (2017). ​PRECAST CONCRETE PROCESS​. ​The
Constructor​. Retrieved 6 June 2017, from
https://theconstructor.org/concrete/precast-concrete-process/6272/
8. Precast Concrete Components | VCES a.s., PREFA​. Retrieved 6
June 2017, from ​http://www.vces-prefa.cz/EN/prefabrikovane-dilce
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20.
Green building (also known as ​green construction or ​sustainable building​) refers to
both a structure and the application of processes that are ​environmentally
responsible and ​resource-efficient throughout a building's life-cycle: from planning to
design, construction, operation, maintenance, renovation, and demolition. This
requires close cooperation of the contractor, the architects, the engineers, and the
client at all project stages. The Green Building practice expands and complements
the classical building design concerns of economy, utility, durability, and comfort.
A similar concept is ​natural building​, which is usually on a smaller scale and tends to
focus on the use of ​natural materials that are available locally. ​
Other related topics
include ​sustainable design and ​green architecture​. Sustainability may be defined as
meeting the needs of present generations without compromising the ability of future
generations to meet their needs. ​
Although some green building programs don't
address the issue of the retrofitting existing homes, others do, especially through
public schemes for energy efficient refurbishment​. Green construction principles can
easily be applied to retrofit work as well as new construction.
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21. CONTENTS PAGES
Abstract 2
Introduction 3 - 5
About Cyberjaya 6
Location 7
Part 1
- District Cooling System
- Recycling Center
- Low Carbon Framework
- Air Quality Monitoring
- Bicycle Route
- Solar Power
- Green Building
- Compostech Machine
9 - 11
12 - 13
14 - 15
16 - 18
19 - 22
23 - 24
25 - 27
28 - 29
Part 2
- District Cooling System
- Solar Power
- Recycling Center
- Air Quality Monitoring
- Compostech Machine
- Green Building
- Bicycle Routes
31 - 32
33
34 - 35
36 - 37
38
39 - 40
41 - 42
Part 3 43 - 48
References 49
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