School of Architecture, Building and Design

Bachelor of Science (Architecture)

BUILDING TECHNOLOGY I
BLD61403

PROJECT 1:
INDUSTRIALISED BUILDING SYSTEM

TUTOR : Mr. Khairool Aizat

Aimuni Khalidah A Bakar 0326074

Chin Vin Yan 0320311
Kimberly Ann Aussie 0325881
Nurul Atika Binte Mohd Gazali 0323246
Ong Tun Cheik 0319939
Rhianna Mae Storey 0325369
CONTENTS PAGE PAGE

1. INTRODUCTION TO IBS 3 5. PRECEDENT STUDY 33

2. INTRODUCTION TO APARTMENT 4-5

6. FABRICATION PROCESS 34- 36

3. DRAWINGS 6-22
3.1 GROUND FLOOR PLAN 7. CONSTRUCTION METHOD 37 - 39

3.2 FIRST FLOOR PLAN

3.3 SECOND FLOOR PLAN 8. JOINT DETAILING 40 -43
3. 4 ROOF PLAN
3.5 ELEVATIONS
9. SCHEDULE 44-48
3.6 CONSTRUCTION DRAWINGS
3.7.1 LOWER GROUND FLOOR PLAN
3.7.2 GROUND FLOOR PLAN 10. IBS SCORE 49
3.7.3 PRECAST CONCRETE SLAB PLAN
3.7. 4 ROOF TRUSSES PLAN
11. CONCLUSION 50
3.7.5 SECTION A-A’ & B-B’
3.7.6 ISOMETRIC VIEW
12. REFERENCE 51
4. PROPOSED SYSTEM & COMPONENTS 23-32

2
1.0 INTRODUCTION TO INDUSTRIALISED BUILDING SYSTEM

IBS Content Scoring System (IBS Score)

● Part 1: Structural Systems (max. score 50 points)

Eg: P.C. concrete beams & columns, steel, prefabricated
timber.

● Part 2: Wall Systems (max. 20 points)

Eg.: P.C. concrete panel, glass, dry partition, block work, etc
Industrialised Building System or better known as IBS amongst the construction and built communities
is the use of prefabricated components in building construction. The construction itself can be ● Part 3: Other Simplified Construction Solutions (max. score
manufactured in controlled environment, either on site or off site. Set up in the 1960’s, IBS begun as an 30 points)
initiative to speed up the delivery time while building affordable quality houses. However, the Eg.: Usage of simplified construction solutions (standard
application and adoption of this method in the local construction industry, is still relatively low components based on MS 1064 and repetition of structural
compared to the developed countries. This was despite the perennial problems besetting traditional layout)
construction methods which include time delay, cost overrun, and waste generation. The Malaysian
government nonetheless sees IBS as the new way forward in the construction industry. The IBS Scoring System is a simple yet effective method of
determining a good project in regards of IBS factors. It is
Principles recommended that IBS may be a suitable option depending on the
construction type, methodologies, site personnel experience and
● Usage of prefabricated and precast components the IBS fabricator
● Off-site production of components
● The use of standardised components
● Repeatability Advantages Of IBS
● Design using modular-coordination concept
● Shorter construction time
There are six main IBS systems identified as being popularly used in Malaysia, namely pre-cast ● Cost savings
concrete framing, panel and box systems, formwork system, steel framing system, timber framing ● Saving in labour
system, blockwork system, and innovative system. ● Less labour at site
● Optimised use of material
Known in maintaining its consistent quality, the IBS system maintains its standards due to factors ● Higher quality and better finishes
where majority of its systems are to be manufactured in production line of the factory. Often ● Flexibility
misinterpreted with a negative image due to its lack of aesthetic value architecturally, the benefits of ● Increased site safety and neatness
IBS systems outweighs its barriers, making it still a favourable choice among the built communities. ● Environmentally friendly

3
2.0 INTRODUCTION TO APARTMENT

INTRODUCTION
The apartment consist of 3 floor which built total of 6 units. The building design is
based on industrialized building system yet it give an aesthetic value by adding brick
on the facade. The idea of expose the material is to showcase the beauty of rawness
yet it embrace the IBS.

4
2.0 INTRODUCTION TO APARTMENT

3 storeys

2 units per floor ( 3

bedrooms, 2 Bathroom)

Sqm : 97.7m2

Exterior: precast concrete

wall and precast brick wall

Interior: partitioned by
drywall system

Precast concrete skeleton

structure

Steel roof trusses for roof

framing

1 flight of precast staircase

per floor

2 extended precast balcony

UNITS FLOOR PLAN

SCALE 1 : 100
5
3.0 DRAWINGS

GROUND FL PLAN
SCALE 1 : 100
6
1ST FLOOR PLAN
SCALE 1 : 100
7
2ND FLOOR PLAN
SCALE 1 : 100
8
ROOF PLAN
SCALE 1 : 100
9
FRONT ELEVATION
SCALE 1 : 100
10
BACK ELEVATION
SCALE 1 : 100
11
RIGHT ELEVATION
SCALE 1 : 100
12
LEFT ELEVATION
SCALE 1 : 100
13
LOWER GROUND FLOOR PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
14
 GROUND FLOOR PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
15
PRECAST CONCRETE COLUMNS PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
16
PRECAST CONCRETE BEAMS PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
17
PRECAST CONCRETE SLABS PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
18
 ROOF TRUSSES PLAN
CONSTRUCTION DRAWING
SCALE 1 : 100
19
SECTION A-A’
SCALE 1 : 100
20
SECTION B -B’
SCALE 1 : 100
21
ISOMETRIC VIEW
N.T.S.
22
4.0 PROPOSED SYSTEMS & COMPONENTS
4.1 Precast Concrete Systems
Types of Precast Systems :
Precast concrete is a construction product produced by casting concrete in a reusable mold or "form" which is
then cured in a controlled environment, transported to the construction site and lifted into place. These Precast systems can be divided into the following categories depending on the load-bearing structure :
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. ● Large-panel systems
Refers to multi-storey structures composed of large wall and floor concrete panels connected in the
Precast concrete building systems are becoming a popular choice for many construction projects in Malaysia vertical and horizontal directions so that the wall panels enclose appropriate spaces for the rooms within
due to the fact that it allows for various design approaches and brings benefits to everyone in the a building. Horizontal elements act as diaphragms that transfer the lateral loads to the walls.
construction team.

Steel reinforcements are used to improve strength and durability of concrete. Steel offers high tension and ● Frame systems
shear strength to make up for what concrete lacks and behaves similarly to concrete in changing Precast frames can be constructed using either linear elements or spatial beam-column
environments, which means it will shrink and expand with concrete, helping avoid cracking. sub-assemblages

This type of construction requires a restructuring of entire conventional construction process to enable ● Slab-column systems with walls
interaction between design phase and production planning in order to improve and speed up construction These systems rely on shear walls to sustain lateral load effects, whereas the slab-column structure
resists mainly gravity loads.

● Mixed systems

Advantages of using the precast system include : Disadvantages of using the precast system include :

● Fast Construction ● Very heavy members

● Scheduling Advantages ● Camber in beams and slabs
● Aesthetic Variety ● Very small margin for error
● High Quality
● Connections may be difficult
● Low Maintenance
● Effective Pricing ● Because panel size is limited, precast
● Safety on Site concrete can not be used for two-way
● Interior Design Flexibility structural systems.
Components of Precast Concrete System
● Efficient Design ● Economics of scale demand regularly shaped
Image Source : http://equusdesign.com/web-pages/precast.htm
● Strong Finish-Approval Process buildings.
Main Features of System : ● Construction Speed
● Joints between panels are often expensive and
● All-Weather Construction
● The division and specialization of the human workforce complicated.
● Efficient Erection
● The use of tools, machinery, and other equipment, usually automated, in the production of standard, ● AII-In-One Components ● Skilled workmanship is required in the
interchangeable parts and products ● Easy Handling application of the panel on site.
● Compared to site-cast concrete, precast concrete erection is faster and less affected by adverse ● Shape and Design ● Cranes are required to lift panels
weather conditions
● Plant casting allows increased efficiency, high quality control and greater control on finishes

23
4.0 PROPOSED SYSTEMS & COMPONENTS
4.1.1 Components of Proposed Precast Concrete System There are three basic configurations of large-panel buildings depending on wall layout:

● Cross-wall systems
Cross walls are load bearing walls whereas the facade walls are non-load bearing. This system is suitable
4.1.1.1 Architectural Precast Concrete Wall Panels for high rise buildings

Precast concrete walls serve two purposes : ● Longitudinal wall systems

Cross walls are non-load bearing whereas longitudinal walls are load bearing walls. This system is suitable
● Stability - holding slabs in place for low rise buildings
● As walls or boxes surrounding staircases and lift shafts
● Two-way systems
Walls can be classified as infill or cantilever : Combination of the above system with all load bearing walls can also be adopted

● Infill walls rely on contiguous composite action with the beam and column frame
● Cantilever walls or boxes act as deep beams to which the frame is attached Suitability of Proposed System in Building:

Load-bearing wall structures are typically used in low and medium-rise residential buildings. These systems are
particularly beneficial when a large quantity of typical housing is required, which allows for the greatest Component used in building : Longitudinal wall panel system
standardization of components.
Reasons :
Advantages of using Precast Concrete Walls :
● More appropriate for low-rise buildings
● Low initial cost ● Load is distributed to both vertical and horizontal components
● Efficient set up allowing for quick enclosing of structure ● Dry wall system is used for interior wall fill
● Continuous construction through variable weather
● Panel’s long-term durability and low maintenance requirement
● Installment requires less scaffolding or formwork
● Straightforward installation of panels and no need to provide joints in precast construction Dry Wall
● Flexibility in wall design
Brick Wall
Transportation of panels have to be handled properly and there is a requirement of special equipment, cranes and
skilled workers during precast construction. Precast Concrete Wall
Plan View

Why Drywall?

Dry construction

Speed of installation

NW Isometric View Lightweight

Flexibility
Examples of Precast Concrete Wall Panel
Image source :http://precast.org/wp-content/uploads/2014/08/Precast-Concrete-Wall-Panel-Install.jpg
Sound insulation
24
4.0 PROPOSED SYSTEMS & COMPONENTS
4.1.1.2. Precast Concrete Beams and Columns Precast Columns

A complete precast concrete structural system offers tremendous advantages and value. Precast columns and Columns are available in a range of shapes, sizes and finishes, can be circular or square and are designed to
beams provide a flexible solution to the structural component of your project. A wide range of options is available incorporate any additional features or fittings. Single storey columns are generally 2.5m - 4m high. Beams
for creating the perfect system to achieve the size and shape required for the building. bear directly on top of these units with a dowelled connection between them. Multi storey columns are cast
with corbels or alternative connections at locations to suit the beams at intermediate levels.
Advantages of using a precast framing system :
Types of Precast Columns :
● Precast beams and columns provide unlimited flexibility in design, shape and application.
● They are extremely durable compared to alternative building materials. ● Edge columns – symmetrical in one direction.
● Beams & Columns work well with other precast components such as Wall Panels and Hollowcore floors to ● Internal columns – symmetrical in all directions.
form a Total Precast
● Precast prestressed beams and columns provide a clean, finished look for the structural component of the ● Corner columns – not symmetrical at all.
building
● Ideal framework for hanging precast panels
● Fast construction
● Structural stability

Types of Precast Columns

http://www.scielo.br/img/revistas/lajss/v8n4/a02fig01.jpg

Suitability of Proposed System in Building:

Component used in building : Single Storey Corbel Column

Precast Column Construction
http://precast.magicrete.in/images/beams_and_columns.png
Every column consists of corbels depending on position of column and
Types of Precast Framing System : placement of load to be carried..

● Precast beam-column sub-assemblages Reason :

Have the advantage that the connecting faces between the sub-assemblages can be placed away from the
critical frame regions ● Structural Stability
● Corbel design enables column to bear structural load
● Linear Elements ● Weight from other components transferred from corbels down
Connecting faces placed at the beam-column junctions. Beams can be seated on corbels at the columns, Into core column
for ease of construction and to aid the shear transfer from the beam to the column. Beam-column joints Image Source : http://www.scib.com.my
/images/product/precast_column/column_type.gif
accomplished in this way are hinged
25
4.0 PROPOSED SYSTEMS & COMPONENTS
Precast Beams

Beam and beam shells are both used for suspended flooring. Beams are typically used as ledges for other
forms of precast flooring to sit on and are generally manufactured to suit each particular situation.

There are two main categories of beams:

1. Internal beams – where floor loading is approximately symmetrical

2. External beams – where floor loading is predominantly non-symmetrical

Corbel Column in Building

Wall panel

Slab
L-Shaped Beam
Precast Beam System
https://theconstructor.org/wp-content/uploads/2012/03/clip_image00221.jpg

Corbel Column
Types of Precast Beams :

● Tee Beams
Exterior Wall Section

Corbels provide support to beams which support wall panels and slabs
Tee beams (either single or double) cover the span range beyond slab-type members such as
hollowcore planks. Tee-beams are a very efficient structural shape. The units are generally cast with
straight strands or deflected strands, depending on design considerations. The tee-beams are the basis
for the design of economical fire rated structures where construction time, long spans or heavy
loadings are important cost influences.

26
 4.0 PROPOSED SYSTEMS & COMPONENTS
● Inverted Tee-Beams Suitability of Proposed System in Building:

Generally use for flooring systems like being an infill where they provide a ledger for precast floor units to Component used in building : Rectangular Beams and L-Shaped Beams
sit on. Inverted tee -beams are structurally similar to a standard single tee-beam.

● Rectangular Beams Reason :

Get their name from the end profile. These beams are generally used to spam clear sections and are ● L-shaped beams used for exterior beams and used to bear load of wall panels
reinforced or prestressed ● Rectangular beams used as interior beams and load is spread equally through longitudinal section
beam
● L-Beams

L beams have an L-shaped profile which provides a ledge for a precast flooring system to sit on.
These beams are generally used to span clear sections and are reinforced and or prestressed.

● Beam shells

This is a complementary composite system of precast elements that contain all the positive main beam
reinforcement and most/all of the stirrups in a minimum volume of concrete for economy and ease of
handling. They are generally ‘U’shaped and mostly used in conjunction with precast flooring such as hollow L-Shaped Exterior Beams in Buildin
core or permanent formwork panels to eliminate on site forming.

● Aashto Beams

Types of Precast Beams

Image source:
http://frontdesk.co.in/big/cm/beams.jpg
Rectangular Beams in Building

Tee Beam
Image source:
https://www.gunungsteel.com/images/stories/gamba
r_teknik/big/t-beam-b1.jpg

27
4.0 PROPOSED SYSTEMS & COMPONENTS
4.1.1.3. Precast Concrete Slabs Single Tee Slab

Single T beam is a loax bearing structure that resembles one T beam connected to a slab. They are used to provide
spans ranging from 30 to 100 feet. Single-tees may be placed flange to flange. Span length ranging from 3.5m to
30m

Suitability of Proposed System in Building.

Component used in building : Hollow Core Slab

Reasons :

Type of Precast Concrete Slabs ● Provide long spans with cross-sections that reduce the height of the building,
https://i.pinimg.com/736x/3b/7d/94/3b7d949656603fc6bfec77bc17b9c31e--what-to-use-precast-concrete.jpg ● saving material cost
● inorganic composition enhances fire protection
Precast Slabs are cast in a factory environment and are a more efficient and cost friendly option for producing
floor panels and roof deck panels. This precast component includes the following prestressed concrete options :

Solid Flat Slab

A flat slab is a two way reinforced concrete slab that usually does not have beams and girders, and the loads are
transferred directly to the supporting concrete columns. Hollow core slabs
https://is.alicdn.com/img/pb/952/998/265/12838
42496609_hz-myalibaba-web6_2543.JPG
The column tends to punch through the slab in Flat Slabs, which can be treated by three methods :
1. With drop panel
2. With column head
3. With both

Hollow Core Slab

Also known as a voided slab, Hollow core slabs are a form of precast slab of prestressed concrete typically used
in the construction of floors in multistorey apartment buildings.

The precast concrete slab has tubular voids extending the full length of the slab, diameter is 2-3 to 3-4. The slabs
are 120cm wide with standard thicknesses between 15cm and 50cm. The size of these elements will typically
range in width from 600 to 2400mm, in thickness from 160 to 500mm, and can be delivered in lengths of up to Slab Layout in Building
24m.

Voids in the hollow core slabs reduce weight and cost and can conceal or cover electrical or mechanical runs.

Double Tee Slab

Two symmetrically placed beams interacting with a slab forming in one section with a “double tee” shape made in
precast, prestressed concrete. Resistant to moisture and corrosion. Parking garages, office buildings, commercial
buildings, factories, industrial buildings are all ideal applications. Each double tee slab is normally 2400mm wide. Local precasters can help determine which sizes, shapes and styles of components will best suit any
Precast beams, precast walls, poured concrete beams and walls, masonry walls, insulated concrete forming individual commercial building project
system walls and structural steel beams are all suitable for use with double tee slabs as load bearing systems. 28
4.0 PROPOSED SYSTEMS & COMPONENTS
4.1.1.4 Precast Concrete Staircase

Three options are available for precast staircases:

● A single precast unit containing all the flights and landings

● Separate precast flights and landings
● Parts of the flights and landings are made in one piece

Staircase Location in Building Plan

Image source : http://bbp.style/PUBLIC/images/website-images/australprecast/AP-Stairs-ProductImage-02-NAT.jpg

Advantages of using Precast Staircase :

1. Provide an unobstructed, early, secure and instant work platform during construction
2. Quick installation time frame
3. Elimination of site shuttering and scaffolding, resulting in reduced construction site costs
4. Quality controlled manufacturing environment allows for repetition of individual components

Suitability of Proposed System in Building

Component used in building : U Shape Stair Single Middle Landing

Reason :

● Suitability with building layout

● Limited stair space
● Easy placement and less needs for jointing systems

Figure : U Shape Stairs

29
4.0 PROPOSED SYSTEMS & COMPONENTS
4.2. Precast Brick Wall Panel System ● Can be manufactured in large sizes; typically grid width x storey height – this lowers cost and increases
the speed of enclosure compared to hand-set brickwork
● Reduces site programme and thus site prelims
Brick-faced precast panels offer all the advantages of the natural materials, but provides a great alternative to ● Reduces number of site movements and waste; tidier, safer environment
traditional construction methods. Brick-faced precast cladding also eliminates most of the concerns associated ● Achieves building weather tightness much quicker
with traditional brick construction. ● No scaffolding required
● Cost efficiencies ● Very low maintenance and lifecycle costs
● Speed of construction ● Offers reduced overall cladding zone (compared to a conventional brick/block cavity wall), resulting in
● Simplified logistics greater net lettable area
● Cost-effective production of large components
● Speedy site times
● No scaffolding/external hoisting Suitability of Proposed System in Building.
● Reduction of wet trades on site
Component used in building : Precast Brick Wall Panels
● Acoustic benefits
● Fire-resistant
Reason :
● Reduction of waste
● Can incorporate pre-installed windows
● Allowance for variation aesthetic value in building
● Efficient method compared to traditional brick method

J Front Ellevation Left Elevation

Image source : http://forterra-precast.co.uk/wp-content/uploads/wall-stacking.png https://www.jacekpartyka.com

Brick-faced cladding advantages:

● Offers designer more scope, as anti-gravity features can be pre-moulded, avoiding need for cumbersome
secondary support on-site
● Enables complex features such as arches without need for centres and site cutting and fitting
● Allows multiple brick finishes in each panel
● Can include windows, doors etc (as with all precast cladding)
● Panels can be pre-insulated
● Components accurately manufactured off-site
Back Elevation Right Elevation
● Greater quality control

Figure : Elevations of building showing brick wall panels 30

4.0 PROPOSED SYSTEMS & COMPONENTS

A truss is essentially a triangulated system of straight interconnected structural elements. The most common use of
4.3 Steel Framing System trusses is in buildings, where support to roofs, the floors and internal loading such as services and suspended
ceilings, are readily provided. The main reasons for using trusses are:

This IBS is commonly used with precast concrete slabs, steel columns/beams and steel framing systems, and ● Long span
is used extensively in the fast-track construction of skyscrapers.
● Lightweight
Apart from that, it is extensively used for light steel trusses consisting of cost-effective profiled cold-formed
● Reduced deflection (compared to plain members)
channels and steel portal frame systems as alternatives to the heavier traditional hot-rolled sections
● Opportunity to support considerable loads.
Advantages of Steel Framing Systems :
● To carry the roof load
● The large-scale benefit of utilizing steel in residential construction is the longevity and durability of the ● To provide horizontal stability.
material itself
● Structurally Light
● Shorter construction timeline
● Takes the element of human error out of the equation Advantages of Roof Trusses :
● Cost savings
● Versatility of steel allowing for variety in design ● Cost effective
● Quick installation
Disadvantages of Steel : ● Heavy equipment to lift not required
● Span across long distances
● They lose strength at high temperatures, and are susceptible to fire. ● High stability due to shape
● They are prone to corrosion in humid or marine environments. ● Triangle shape allows weight that is applied to sides to be redistributed down and away from center

Disadvantages of Roof Trusses :

4.3.1 Components of Proposed Steel Framing System ● High Fabrication cost
● Rusting may occur
4.3.1.1 Steel Roof Trusses ● High heat conductivity of metal requires careful incorporation of insulation into the roof structure

Common types of Steel Roof Trusses :

Left : https://sc01.alicdn.com/kf/HTB1tKjlFpXXXXaiaVXXq6xXFXXX0/200459693/HTB1tKjlFpXXXXaiaVXXq6xXFXXX0.jpg
Right : http://bmmetalroofing.com/wp-content/uploads/2014/06/NuTruss_Brochure-2_11.jpg
Image source : http://www.barntoolbox.com/images/RoofTrussTypes.jpg

31
4.0 PROPOSED SYSTEMS & COMPONENTS
Suitability of Proposed System in Building.

Component used in building : Mono-Pitch Roof Steel Structure

Reason :

● Lightweight structure compared to the other precast components

● Simple yet effective form of steel roof truss

Roof over Trusses

Steel Roof Trusses without Roof

Back elevation of Roof Trusses

32
5.0 PRECEDENT STUDY

1. SERI KASTURI, SETIA ALAM 2. MELROSE COMMONS II APARTMENT

LOCATION: Bandar Setia Alam, LOCATION: Melrose Ave, Bronx, NY,USA
Shah Alam, Selangor, Malaysia
COMPLETE YEAR : 2001
COMPLETE YEAR : 2015
PRECASTER : Oldcastle Precast
Building Systems
PRECASTER : Setia precast Sdn.
Bhd. ARCHITECT : Danois Associates, New
York City
3-bedroom, 2-bathroom unit
FACT : 130,000 SF hollowcore
10 floor - 950 built up

DESIGN INTRODUCTION PRE-ASSEMBLE BRICK PANEL

To achieve the “masonry”
KITCHEN aesthetic effect, a brick fecade
The design of the Melrose Commons II, a 30 was pre-assemble on the
BEDROOM apartment are unit multifamily affordable- external wall panel. Beside that,
DINING
ROOM
2
horizontal and vertical housing in New York City .The precast lintel and cornice were
homes feature an all-precast added to enhance the detail.
repetition structure.
LIVING BEDROOM Hence, it achieve a concrete design that the
ROOM 1
MASTER
good design of developer agreed to try after
BEDROOM PRECAST CONCRETE WALL
modularity. Next, The meeting with the precaster PANEL were installed for internal
whole building is and being convinced of the partition and also act as a parti
repetition of floor to benefits. Despite the wall. Despite that, it also act as
INTRODUCTION floor height all the conveniences that ease the a load bearing walls which
supported the whole structure.
way to 10st floor. construction process, the
Seri Kasturi Setia Alam is a Beside that, the building also achieve the
middle-cost apartment developed design of building is aesthetic value that fit into
by S P Setia and using precast the context. Beside that, the HOLLOWCORE SLAB were plank
base on Malaysia
building had awarded multiple over the precast concrete wall
construction method that supply Standard panel. To joint both component
by Setia Precast sdn. Bhd. The (MS1064). Butterfly awards for being
together, i-Beam were installed
apartment used precast concrete roof is design because industrialized building into the pre-assemble brick
which suitable in a humid context of the climate in system that benefit in the panel’s column.
in Malaysia. Malaysia. construction industry.
33
6.0 FABRICATION PROCESS
5.1 Precast Concrete System
IBS methods focuses on the concept of prefabrication where a single housing unit is broken into different
components such as the floors, walls, columns, beams and roof, and having these components prefabricated ● Providing blockouts and grout ports for dowel bars and tie bars
or manufactured in modules in a factory.
● Providing panel undersealing
A well established practice, the production of precast concrete has been developed to regulate the quality of Cement grouts are primarily used for the undersealing of precast. Undersealing helps will voids that
precast concrete production processes. With efficiency and cost benefits in production, multiple modular occurring voids that may exist under the panel and ensure full contact.
panels are easily produced in a day.
● Placing concrete
Process: Once the formwork is ready, concrete is delivered to the formwork using a transit mixer or buckets within
the precast plant complex. Typically, there are two concrete types and placement processes, namely slump
● Setting up formwork concrete and SCC.
The formwork used for fabricating precast concrete is made of sturdy steel members that are locked
into place on flat steel casting beds. Precasting allows the use of high quality formwork such as
vibrating casting tables and accurate positioning of inserts, where the formwork can retain tight
dimensional tolerances over repeated use.

Image source : https://www.nap.edu/read/22710/chapter/11#89

Image source : https://www.nap.edu/read/22710/chapter/11#89

Slump concrete requires moving the concrete manually within the formwork and consolidated using a spud
vibrator. It is then finished with a metal straightedge or hydraulic powered roller screed. SCC however is
● Installation of hardware (Reinforcement, prestressing steel) deposited across the formwork without compaction effort or manual manipulation.
As reinforcement is placed in both directions and typically placed in two layers, nominal reinforcement
is required to mitigate the concrete stress encountered in delivery. Ducts are positioned straight and
not allowed to bow under the weight of concrete as it is poured into the formwork.

Image source : https://www.nap.edu/read/22710/chapter/11#89

Image source : https://www.nap.edu/read/22710/chapter/11#89

34
6.0 FABRICATION PROCESS
● Controlled pouring environments in the factory reduce concrete curing times through the use of ● Conducting QA/QC activities
temperature control and advanced mix design, including low water to cement ratios. The placement The precast system typically ensures concrete durability and strict tolerances to minimise
rates are maintained as panel production is not affected by external factors such as weather installation-related issues. Quality Control carries out tests and certifications assuring the correct
conditions and traffic delays. Therefore, concrete is usually produced as needed on a just-in-time basis specification of materials and equipment meet the project specification requirement while Quality
Assurance is usually done by third-party organisation.
● Stripping forms
To allow the next set of panels to be fabricated, a timeframe of 15 to 20 hours is allowed where the
panels are stripped of formwork.

Image source : https://www.nap.edu/read/22710/chapter/11#89

● Delivery
Image source : https://www.nap.edu/read/22710/chapter/11#89 The erection sequence would determine the order of transport where careful planning can minimise
transport and costs. Large linear precast concrete elements can be transported by overhead cranes directly
from the production shop and loaded onto trucks to site.
● Applying finishing details
The day-old panels may be moved to other areas where finishing details can be taken care of, such as: ● Installation
○ Cleaning of blockouts Ready for assembly, the IBS components are assembled with the assistance of a crane. As specialised
○ Installing foam strips lifting equipment are required, specialised contractors will be needed. The final unit of the building is now
○ Applying project assembled and ready for occupation.
○ Cutting pretension tendons
○ Checking for damage

● Cutting and storing panels

Once the finishing details and curing membrane has been completed, the precast concrete is moved
for storage. It is cured at the plant and typically stored for a week to a few months until installation.

Image source : https://www.nap.edu/read/22710/chapter/11#89

Image source : https://www.nap.edu/read/22710/chapter/11#89

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6.0 FABRICATION PROCESS
5.1.1 Components
5.2 Steel Framing System
Precast Hollow core Slab
Most steel construction is done with a type of steel called mild steel. Mild steel is a material that is immensely
Processed under quality controlled conditions in specialised
strong.
environments, hollow core slabs can be produced. The dry cast
production system uses the extrusion method of forming
precast voided slabs thus slab extruders are used. Cutting & Drilling
In the fabrication factory one of the first operations is to cut the sections to length and profile the plates to the
desired size or shape. Circular Saws are used for cutting to length.

Drilling & Punching

Column and Beam
To allow system to be rapidly bolted together on site, all holes are pre drilled or punched in the fabrication factory.
For drilling, high speed steel twist bits are used. The rotating bit cuts through the steel and the metal being
The use of columns and beams makes an ideal framework for
removed during the process forms swarf (the curls of metal that spiral off during machining). The swarf travels up
hanging precast panels, offering fast construction, structural
the flutes , which run up the side of the bit.
stability and enhanced fire resistance.

Shot Blasting
Once the steel is cut to preferred length it will undergo shot blasting process. It is used for surface preparation
which is an important part of the fabrication process, that is essential to provide a suitably clean finish for welding
and subsequently producing a keyed surface ready to accept paint. Shot is fired at the steel making the force of the
shot against the surface displaces dirt and scale.

Primers
Precast Wall
Prefabrication primers are then applied, immediately after blast cleaning, to maintain the reactive blast cleaned
surface in a rust free condition through the fabrication process until final painting can be undertaken. When paint is
Precast panels are manufactured in a manufacturer plant by
sprayed onto this clean abraded surface it adheres well and provides a longer life for the paint system.
casting the concrete into the formwork. It will then be ready to
install after it is delivered to the jobsite where each panel is
designed according to engineering standard to withstand for
each structural load.

Staircase

Able to be produced as straight flights with separate or

attached landings, precast staircase offers finished landings
and hidden connections with design practicability. Installation
is efficient and ready to use with immediate access, improving
site safety.

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7.0 CONSTRUCTION METHOD
The IBS method differs from the conventional construction method. Known for its multiple benefits such as
shorter construction time, material saving and immunity to weather changes, IBS acts as an alternative
approach to the existing conventional building system.

IBS construction stages :

COMPONENT PRODUCTION COMPONENT DELIVERY COMPONENT ASSEMBLY LIFTING PLACING

CONNECTING M&E WORKS FIXTURES INSTALLATION FINISHING

7.1 CONSTRUCTION METHOD & SEQUENCE

7.1.1. LOWER GROUND

Starting with the excavation of the site, it is levelled to allow straight alignment of precast components. Pad
footings with protruding column stumps are then assembled on site followed by ground beams. Precast
columns are installed on top of the precast stumps by bolting connections where the baseplate can be welded
to the bottom of the embed. The slab is then installed and the lower ground construction is complete.

1. 2. 3.

4. 5.

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 7.0 CONSTRUCTION METHOD
7.1.2 GROUND FLOOR

The L-beams on ground level are rested on the column corbel via steel angles that are welded to metal plates 3. 4.
casted into the beams and columns itself. Once the skeletal structure is intact, the wall panels are slotted
into place. Non-loadbearing walls such as exterior precast concrete walls and interior drywalls are installed.
The staircase with anchor plates are then slotted onto the landing, where the gaps are grouted with cement.

1. 2.

7.1. 4 SECOND FLOOR

7.1.3 FIRST FLOOR
The construction sequence is repeated where the column (FF) to column (SF) are connected by metal bearing
The hollow core slabs are installed and supported on L-beam (exterior) rectangular beam (interior) where plates and embedded anchor bolts that are casted into both ends and grouted. Beams, walls and staircase are
reinforcement bars are inserted between the slabs and grouted with cement, securing them in place. The as followed.
construction sequence is repeated where the column (GF) to column (FF) are connected by metal bearing
plates and embedded anchor bolts that are casted into both ends and grouted. Beams, walls and staircase are
as followed. 1. 2.
1. 2.

38
 7.0 CONSTRUCTION METHOD

3. 4.
7.1.6 M&E WORKS, FIXTURES & FINISHING

Lastly, M&E works and fixtures such as doors, windows and railings are installed. Finishing works for slabs and
walls such as water proofing layer are carried out as well.

7.1.5 ROOF

The unit is designed with a mono pitched roof. After the construction of the superstructure, prefabricated
steel roof truss are secured into the beams with connections of L-plates and bolts. The rafter supports the
materials of roof claddings with beams preventing them from deflection. Pieces of corrugated aluminium are
screwed onto the purlins bottom up along with rockwool insulation, vapour barrier, trapezoidal galvanised steel
sheet underneath.

1. 2.

39
8.0 JOINT DETAILING
COLUMN TO FOOTING COLUMN TO COLUMN

Pad footings with protruding column stumps are assembled on site followed where the precast Metal bearing plates and embedded anchor bolts are cast into the ends of the columns. After the
columns are installed on top of the precast stumps. The column and footing are connected by columns are mechanically joined, the connection is grouted to provide full bearing between
bolting connections where the baseplate can be welded to the bottom of the embed, leveling elements and protect the metal components from fire and corrosion.
the nuts on the anchor bolts. The column can be lowered in place and now bolted.

Precast column

Concrete slab
Concrete pour
back

The entire
Shins joint is
dry-packed
with grout
after
alignment
Baseplate over
non-shrink grout

BEFORE ASSEMBLY ASSEMBLED GROUTED

SECTION OF PAD FOOTING

TO COLUMN CONNECTION

40
 8.0 JOINT DETAILING
BEAM TO COLUMN SLAB TO BEAM & SLAB TO SLAB

Beams are set on bearing pads on the column corbels. Steel angles are welded to metal plates cast The hollow core slabs are installed and supported on L-beam (exterior) rectangular beam
into the beams and columns and the joint is grouted solid. (interior) where reinforcement bars are inserted between the slabs and grouted with cement,
securing them in place.

Metal plates cast

Rebate cast in floor

slab for angle
connection

EDGE SUPPORT

IN-SITU CONCRETE

Bearing pads

EXTERIOR L-BEAMS - INTERIOR RECTANGULAR BEAMS - INTERNAL SUPPORT

COLUMN CONNECTION COLUMN CONNECTION

41
 8.0 JOINT DETAILING
WALL TO BEAM STAIRS TO SLAB

Walls are slotted into place after framing structure is intact. Wall panels are either made with The staircase with anchor plates are then slotted onto the top and bottom landing. The gaps
grooves to be permanently fixed in but can also be bolted or welded into place. Instead of arranging are then grouted with cement.
the L-beam inward, the arrangement of face outward allow the slotting of the brick wall into the
L-beam and helps prevent water leakage from the exterior.
Top landing
Precast connection
Brick Wall

Rebate cast in
floor slab for
angle connection
Rebate cast in floor
slab for angle
connection

L-beam Bottom landing

connection
SECTION CUT OF EXTERIOR SECTION CUT OF
WALL AND BEAM STAIRCASE

42
9.0 SCHEDULE

43
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45
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10.0 IBS SCORE

48
11.0 CONCLUSION

In Building Technology 1, it introduces us to a more extensive study of building construction by

exposing us to the latest technologies implemented in the industry today. Through this project, we
enable to experience the whole process of construct an IBS building by design a 3 storeys
residential apartment, understand the construction method of IBS, calculate the IBS score and
experimental with model making.

The process of design is needed to implement the MS 1064 in order to achieve the required
modularity system. Hence, the process of design is critical and yet need to be achieve with the
practicality. Beside that, we were to purpose the industrialized building system that suit the most
for our design. Thus, we get to understand the methodology of IBS construction and the details that
joint each components. After proposing the system, we then need to calculate the IBS score for our
apartment. From there, we enable apply the calculation method of Part1, 2 and 3 that we learn prior
in the class. Last but not least, model making enable for us to experiment the workability of IBS
construction in our building and also understand the construction sequence of the IBS.

In this project, many of the detail need to be take note in order to minimise mistake. Therefore,
teamwork and communication is needed. Aside from that, this project had introduced us the latest
technology in the our building industry and also allow us to achieve a design which is practical,
sustainable, and efficient.

Final sectional model

50
12.0 REFERENCES
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2. Industrialized Building System (IBS). (n.d.). Retrieved October 08, 2017, from http://www.malaysiaconstructionservices.com/services/industrialized-building-system-ibs

3. SAHIL KUMAR, Student at LPU Follow. (2016, May 14). Prefabricated wall panel. Retrieved October 08, 2017, from

https://www.slideshare.net/SAHILKUMAR157/prefabricated-wall-panel

4. (n.d.). Retrieved October 08, 2017, from http://www.dubaiprecast.ae/system

5. A. (2013, July 28). Precast concrete. Retrieved October 08, 2017, from http://www.yourhome.gov.au/materials/precast-concrete

6. PRECAST COncrete STRUCTURE. (n.d.). Retrieved from http://paradigm.in/wp-content/uploads/2015/01/5-PRECAST.pdf

7. Columns And Beams, Precast Columns And Beams. (n.d.). Retrieved October 08, 2017, from http://www.oreillyconcrete.com/products/columns-beams/

8. Mishra, G. (2017, September 12). Types of Precast Components in a Building. Retrieved October 08, 2017, from

https://theconstructor.org/concrete/types-of-precast-components-in-a-building/6325/

9. Sagar Shah Follow. (2016, April 23). PRECAST BUILDING SYSTEM. Retrieved October 08, 2017, from https://www.slideshare.net/SagarShah118/precast-building-system

10. Concrete, C. (n.d.). Precast Concrete Columns and Beams. Retrieved October 08, 2017, from

http://www.creaghconcrete.co.uk/products/precast-frames/precast-concrete-columns-beams.html?p=198

11. Brick-faced Panels. (n.d.). Retrieved October 08, 2017, from http://techrete.com/products/finish/brick-faced-panels/

12. T. (2011, September 22). Advantages and Disadvantages of Precast Concrete Construction. Retrieved October 08, 2017, from

https://cw2011workshop05.wordpress.com/2011/09/22/advantages-and-disadvantages-of-precast-concrete-construction/

13. Melrose Commons II. (n.d.). Retrieved October 08, 2017, from

http://www.pcine.org/projects/project.cfm?categoryIDs=&articleID=08447A69-F1F6-B13E-838416AE5F62F91E&pageNumber=2

14. (n.d.). Retrieved October 08, 2017, from http://www.setiaprecast.com.my/current_project_residential.asp

15. (n.d.). Retrieved October 08, 2017, from http://www.creativeptsb.com/project-references.htm

16. Http://ljournal.ru/wp-content/uploads/2016/08/d-2016-154.pdf. (2016). doi:10.18411/d-2016-154

17. Http://www.astm.org/JOURNALS/FORENSIC/PAGES/JFS2004186.htm. (2004). Journal of Forensic Sciences, 49(6), 1-1. doi:10.1520/jfs2004188

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