Title: Construction Technology Ii Course Work Report: Siti Nadiah Binti Mokhtar Noor Safika Faezan Binti Azahari

TITLE:
CONSTRUCTION TECHNOLOGY II
COURSE WORK REPORT
Group Name:
SITI NADIAH BINTI MOKHTAR
NOOR SAFIKA FAEZAN BINTI AZAHARI
Subject: CONSTRUCTION TECHNOLOGY II (SBEQ1122)

Course: Bachelor of Quantity Surveyor Year: 1 SBEQ – 2011/2012
Submission & Presentation Date: Week 15
Lecturer: AMINUDIN ALI
DEPARTMENT OF QUANTITY SURVEYING
FACULTY OF BUILT ENVORONMENT
UNIVERSITI TEKNOLOGI MALAYSIA
SKUDAI JOHOR
COURSE WORK AMIN/SBEQ1122 TECH2/FEB12
CONSTRUCTION TECHNOLOGY 2 SBEQ 1122

Lecturer : Aminudin Ali (Room: B11 224 – 01)
Subject : Construction Technology SBEQ 1122
Allocated Marks :Coursework 30% & Presentation 10%
Course Work Instruction
The aim of this coursework is to develop an understanding of construction technology and its application to the
construction of medium span, low-rise commercial, industrial and community buildings. It will examine the processes
and techniques related to the construction of substructures, frames, enclosure and finishes for medium span, low-rise
commercial, industrial and community buildings. The coursework will provide students with construction knowledge to
be applied in other courses such as estimating, measurement, construction planning and services. The courseswork
also provides the environment to develop students’ ability to communicate technical information graphically and to work
effectively as a team member to achieve mutual objective.
You are required to form a group consist of approximately 11 to 22 multi racial members each. (Upon approval by
lecturers)
The group must identify construction sites and for the a case study of the followings topics:
The method and process of construction, fixing and/or assembling, construction detailing of various elements and
components
1) Substructure: Deep Foundation, Piling Works & Sheet Pile.
2) Substructure: Basement Construction & Diaphragm Wall.
3) Substructure: Retaining Wall System, Earthwork Support And De-Watering System.
Detail study component parts of buildings superstructure including; types of construction or systems for the parts of the
components; function for the parts of the component; construction details; materials used to construct part of the
component; types of finishes for the parts of the component; construction process, method and provision for
construction or fixing of the following structure components for commercial & industrial buildings:
4) Superstructure:: Industrialised Building System (IBS), pre-fabricated and composite.
5) Superstructure:: Steel Frame Members framing system.
6) Superstructure:: Upper Floors.
7) Superstructure:: Roof medium and large span.
8) Superstructure:: External Walls-Cladding, curtain walling, infill panelling system.
9) Superstructure:: Partitions & Ceiling-Demountable partitions & suspended ceiling.
10) Superstructure:: Door & Window- for commercial and industrial building
11) Superstructure:: Stairs-Concrete, metal, timber and composite stairs.
A construction site case study is a must. Further outline and detail circumstances will be discussed for each group.
Apart from this directive, additional instruction and information will be given as it seems fit depending on the related
problems discussed during the tutorial session. Tutorial for each group must be done fairly and accordingly, controlled
by the class representative and group leader without any dispute in regarding the time period spend for each group.
A report must be made in the form of softcopy and consist of the followings:
 Recognise the alternatives available for the construction of medium span, low-rise commercial, industrial and
community buildings.
 Describe the basic construction vocabulary for understanding of construction technology and its application in
medium span, low-rise commercial, industrial and community buildings.
 Sketch & illustrade the construction techniques and methods used in the construction of substructures and
superstructures of medium span, low-rise commercial, industrial and community buildings
 Communicate technical information graphically.
 Work effectively in a team.
 Related brochures/ catalogs/pamphlets etc.
 Measurement & Cost for each types.
Date of submission: Week 15
Date of presentation: Week 15
Presentations are expected to be in the form of Powerpoint only.
All submission must be in CD or Pen drive form including all brochures / catalogs / pamphlets etc.
i
AMIN/SBEQ1122 TECH2/FEB12
PREFACE
Assalamualaikum w.h.b. our group has been given the topic about
Industrialised Building System as our project assignment. We are mainly
consists of two group members which Siti Nadiah binti Mokhtar and Noor
Safika Faezan binti Azahari from 1SBEQ. We would like to thank our parent
for giving us support in finishing the project. They pay the fees of the trip to
site for us and also buy us a camera for taking the photos. Without the
economics support for parent this project would not be completed.
We feel very grateful that we are able to complete this assignment in a

given time. A very much gratitude to each group members for their entire
corporations in order to finish this assignment with a satisfactory resulted.
Thank you also to the group members for making much effort to getting the
site for the case study of this assignment. Without their corporation this
assignment may not be completed.
ii
ACKNOWLEDGEMENT
First and for most, we would like to thank to our lecturer of subject
Construction Technology II, Encik Aminudin Ali for giving a chance to us to do
this assignment. His encouragement supports and guidance from the initial to
the final very much help us His willingness to give his time so generously has
been very much appreciated. Without him, we may not be able to finish this
assignment with good and well outcome
Our grateful thanks also go to Mr Ridhwan as the supervisor site at the

TERAJU CONSTRUCTION Sdn. Bhd which has helped us a lot during our
case study. The contribution and support he gave truly help our progression
and smooth our coursework progression. Besides, thank you also for other
TERAJU CONSTRUCTION Sdn Bhd members for allowing us to use their
construction project as our site for case study as without that we would have
face much difficulties.
Great deals appreciated to the Perpustakaan Sultanah Zariah, UTM

that has given many resources of books and journal for us. It is very much
resourceful as our reference in doing this coursework.
Last but not least, we would like to thank to all who have been involved
directly or indirectly during completing this assignment.
iii
TABLE OF CONTENT
page
COURSE WORK INSTRUCTION ………………………………………………………………….i
PREFACE.…………………………………………………………………………………………….ii
ACKNOWLEDGEMENT………………………...…………………………………………………..iii
TABLE OF CONTENT………………………………………………………………………..……iv-v
LIST OF FIGURES …..…………………….………………………………..……………………….vi
LIST OF TABLE…………………………………………………………………………………….. vii
1 INTRODUCTION ........................................................................................................................... 1
1.1 INTRODUCTION OF THE STUDY ................................................................................................. 1
1.1.1 Statement of problem .................................................................................................... 2
1.2 BACKGROUND OF STUDY .......................................................................................................... 3
2 INDUSTRIALISED BUILDING SYSTEMS (IBS) ...................................................................... 4

2.1 DEFINITION ........................................................................................................................... 4
2.2 HISTORY CHRONOLOGY OF HOUSING ......................................................................... 5
2.3 PRINCIPLE ............................................................................................................................. 7
2.4 WHAT IBS IS ALL ABOUT ................................................................................................... 10
2.5 OBJECTIVE OF IBS ............................................................................................................ 11
2.1 CLASSIFICATION OF BUILDING SYSTEM .................................................................... 12
2.1.1 CONVENTIONAL CONSTRUCTION METHOD ..................................................... 14
2.1.1.1 Casts-in-situ Construction Method ....................................................................................... 14
2.1.1.2 Composite Construction Method .......................................................................................... 14
2.1.1.3 Pre-fabricated Construction Method .................................................................................... 15
2.2 CLASSIFATION OF IBS...................................................................................................... 16
2.2.1 CONVENTIONAL CONSTRUCTION METHOD ..................................................... 16
2.2.2 LINEAR SYSTEM OR FRAMES (BEAMS AND COLUMN) .................................. 16
2.2.3 PANEL SYSTEM.......................................................................................................... 16
2.2.4 RECTANGULAR OR BOXES SYSTEM OR TRHEE DIMENSIONAL SYSTEM 18
2.3 CLASSIFICATION ACCORDING TO MATERIAL ........................................................................... 19
2.3.1 TIMBER ......................................................................................................................... 19
2.3.2 BRICK AND BLOCK WORK ...................................................................................... 19
2.3.3 STEEL ........................................................................................................................... 19
2.3.4 REINFORCED CONCRETE ...................................................................................... 19
2.4 CLASSIFICATION ACCORDING TO RELATIVE WEIGHT OF COMPONENTS .................... 20
2.5 FIVE MAJOR GROUPS OF IBS ......................................................................................... 21
2.5.1 PRECAST CONCRETE FRAMING, PANEL AND BOX SYSTEM ....................... 21
2.5.2 STEEL FORMWORK SYSTEMS .............................................................................. 21
2.5.3 STEEL FRAMING SYSTEMS .................................................................................... 21
2.5.4 TIMBER FRAMING SYSTEMS.................................................................................. 21
2.5.5 BLOCKWORK SYSTEMS .......................................................................................... 22
2.6 SYSTEM OF IBS ................................................................................................................... 27
2.6.1 CLOSED SYSTEM ...................................................................................................... 27
2.6.2 OPEN SYSTEM ........................................................................................................... 28
2.7 MODULAR COORDINATION IN IBS ................................................................................. 29
2.7.1 BENEFIT IMPLEMENTING MODULAR COORDINATION ................................... 31
2.7.2 BENEFIT IMPLEMENTING MODULAR COORDINATION ................................... 31
2.7.2.1 The use of modular ................................................................................................................ 31
2.7.2.2 A reference system to define coordinating spaces and zones for building elements and
assemblies ................................................................................................................................................ 32
2.7.2.3 Rules for locating building elements within reference system ......................................... 32
2.7.2.4 Rules for sizing of building components .............................................................................. 32
2.7.2.5 Rules defining preferred size for building components and coordinating dimensions for
those building............................................................................................................................................ 32
2.8 MATERIAL AND COMPONENT ........................................................................................ 33
2.8.1 MATERIAL .................................................................................................................... 33
2.8.2 COMPONENT .............................................................................................................. 34
2.9 TYPES OF CONNECTION .......................................................................................................... 35
2.9.1 PINNED CONNECTION ............................................................................................. 35
iv
2.9.2 MOMENT RESISTING CONNECTION .................................................................... 38

2.9.3 RIGID CONNECTIONS............................................................................................... 38
2.10 STRUCTURAL MEMBER CONNECTION ................................................................... 41
2.10.1 COLUMN CONNECTIONS ........................................................................................ 41
2.10.2 COLUMN TO BASE CONNECTIONS ...................................................................... 41
2.10.3 COLUMN TO BEAM CONNECTIONS ..................................................................... 42
2.10.4 CONNECTIONS OF HOLLOW CORE SLAB .......................................................... 42
2.10.5 FOUNDATION CONNECTIONS ............................................................................... 43
2.10.6 BEAM CONNECTIONS .............................................................................................. 43
3 INSTALLATION OF PRECAST INDUSTRIALISED BUILDING SYSTEMS (IBS) ........... 44
3.1 INSTALLATION ......................................................................................................................... 44
3.1.1 SHIPPING NOTIFICATION ........................................................................................ 44
3.1.2 BEFORE ORDERING ................................................................................................. 44
3.1.3 TRANSPORTATION ................................................................................................... 45
3.1.4 SITE STORAGE ........................................................................................................... 45
3.1.5 HOISTING ..................................................................................................................... 46
3.1.6 PLACEMENT ................................................................................................................ 46
3.1.7 FIELD REPAIRS AND MODIFICATION ................................................................... 47
3.2 CONSTRUCTION SEQUENCE OF PRECAST CONCRETE STRUCTURES .................. 47
3.3 ADVANTAGES AND DISADVANTAGES OF IBS ........................................................... 49
3.3.1 ADVANTAGES ............................................................................................................. 49
3.3.2 DISADVANTAGES ...................................................................................................... 50
3.4 COMPARISON BETWEEN SYSTEM IBS AND CONVENTIONAL METHOD ............ 51
3.5 BARRIERS TO THE ADOPTION OF IBS IN MALAYSIA ................................................ 52
3.6 METHODOLOGY .................................................................................................................. 53
4 CASE STUDY .............................................................................................................................. 54

4.1 COMPANY PROFILE .......................................................................................................... 55
4.2 VISION................................................................................................................................... 56
4.3 MISSION ............................................................................................................................... 56
4.4 COMPANY MOTTO ............................................................................................................. 56
4.5 QUALITY POLICY STATEMENT ....................................................................................... 57
4.6 ORGANIZATION CHART ................................................................................................... 58
4.7 PROJECT PROFILE............................................................................................................ 59
4.8 THE PRECAST CONCRETE COMPONENT USED BY THE PROJECT .................... 61
4.8.1 CONNECTION OF THE PRECAST CONCRETE .................................................. 65
4.8.1.1 Column to column connection .............................................................................................. 65
4.8.1.2 Column to beam connection ................................................................................................. 66
4.8.1.3 Column to base connection................................................................................................... 67
4.8.1.4 Column to slab connection .................................................................................................... 68
4.8.1.5 Slab to slab connection.......................................................................................................... 69
4.8.2 The Manufacturing of Precast Concrete ( column) ................................................. 70
4.8.3 Erection Procedure ...................................................................................................... 74
4.8.4 INSTALLATION OF PRECAST CONCRETE COLUMN ........................................ 82
4.8.5 INSTALLATION OF PRECAST CONCRETE BEAM .............................................. 84
4.8.6 INSTALLATION OF PRECAST CONCRETE FLOOR SLAB ................................ 86
4.8.7 INSTALLATION OF PRECAST CONCRETE STAIRCASE .................................. 87
4.8.8 PLANTS AND MACHINERIES .................................................................................. 89
4.9 PROBLEM DURING CONSTRUCTION OF PROJECT ................................................. 91
4.9.1 Problem Solving ........................................................................................................... 92
5 BUDGET AND EXPENSES FOR THE COURSE WORK ..................................................... 95
6 CONCLUSION ............................................................................................................................. 96
7 BIBLIOGRAPHY / REFERENCES ........................................................................................... 97
A. REFERENCES ......................................................................................................................... 97
B. BIBLIOGRAPHY .................................................................................................................. 98
8 APPENDIX.................................................................................................................................... 99
v
LIST OF FIGURES
page
Figure 1 : Type of Building System in Malaysia .............................................................................. 13

Figure 2 : Frame System .................................................................................................................... 17
Figure 3 : Panel System ..................................................................................................................... 17
Figure 4 : Box System ......................................................................................................................... 18
Figure 5 : Examples of Linear Systems for Industrialised Buildings ............................................ 22
Figure 6 : Typical Linear Prefabricated Elements ........................................................................... 23
Figure 7 : Typical Schemes of Industrial Linear .............................................................................. 24
Figure 8 : Different System of Planar System ................................................................................. 25
Figure 9 : Precast Floor Elements ..................................................................................................... 25
Figure 10 : A Generic Precast Concrete Framed Building ............................................................ 26
Figure 11 : Comparison between Unstable Frame and Stable Frame ........................................ 35
Figure 12 : Pinned Connection with Steel Inserts ........................................................................... 36
Figure 13 : Plates or Steel Sections are anchored into the Components ................................... 36
Figure 14 : Example of Pinned Connection ..................................................................................... 37
Figure 15 : Example of Rigid Connection ......................................................................................... 39
Figure 16 : Rigid Beam-to-column Connection ............................................................................... 39
Figure 17 : Rigid Beam-to-column Connection ............................................................................... 40
Figure 18: Methodology of IBS .......................................................................................................... 53
Figure 19 : Drawing of column ........................................................................................................... 61
Figure 20 : column ............................................................................................................................... 61
Figure 21 : Drawing of beam .............................................................................................................. 62
Figure 22 : Beam at site ...................................................................................................................... 62
Figure 23 : Beam ................................................................................................................................. 62
Figure 24 : view of slab ....................................................................................................................... 63
Figure 25 : Slab at the storage .......................................................................................................... 63
Figure 26 : view of staircase .............................................................................................................. 64
Figure 27 : staircase at site ................................................................................................................ 64
Figure 28 : Drawing of column to column......................................................................................... 65
Figure 29 : column under construction ............................................................................................. 65
Figure 30 : View of column to beam ................................................................................................. 66
Figure 31 : Column to beam under construction ............................................................................. 66
Figure 32 : Column to footing ............................................................................................................. 67
Figure 33 : column to base under contruction ................................................................................. 67
Figure 34 : Slab column edge connection ........................................................................................ 68
Figure 35 : Column to slab under construction ............................................................................... 68
Figure 36 : Plank to plank connection............................................................................................... 69
Figure 37 : Slab to slab on site .......................................................................................................... 69
Figure 38 : Erection Procedure Stage 1 to 3 ................................................................................... 74
Figure 39 : Erection Procedure Stages 4 to 6 ................................................................................. 75
Figure 40 : View the starter bar ......................................................................................................... 76
Figure 41 : Show the starter bar ........................................................................................................ 76
Figure 42 : View to put the column.................................................................................................... 77
Figure 43 : Construct column on site ................................................................................................ 77
Figure 44 : View of beam to column ................................................................................................. 78
Figure 45 : Construct beam to column ............................................................................................. 78
Figure 46 : view of beam to column .................................................................................................. 79
Figure 47 : Construct beam to column ............................................................................................. 79
Figure 48 : View grouting the precast ............................................................................................... 80
Figure 49 : Grouting on site ................................................................................................................ 80
Figure 50 : View cast in situ ............................................................................................................... 81
Figure 51 : Cast in situ concrete ........................................................................................................ 81
Figure 52 : How to unload components edge lift and single row .................................................. 92
Figure 53 : How to unload components single row and double row ............................................ 92
Figure 54 : How to unload component 4 high and 2 high .............................................................. 93
Figure 55 : How to unload components 3 high equal and 3 high double load ............................ 93
Figure 56 : How to stabilize the component ..................................................................................... 93
vi
LIST OF TABLE
TABLE 1 : Building System Classification According to Relative Weight of Component.........20

TABLE 2 : Budget for the course work 94
vii
1 INTRODUCTION
1.1 INTRODUCTION OF THE STUDY
This section discusses the introduction of the study. It consists of 7 main subsections
Which are background of the study, statement of problem, purpose of the study, objectives of
the study, research questions, and significance of the study and scope of the study.
Nowadays, technology becomes the greater aspect to our life. Everything in this world
involves technology and science and it’s become really crucial to humans and also a vital
aspects regarding to construction technology. They do also use Timber buildings too, various
laminates, precast concrete, etc. These are termed dry constructions as opposed to the "wet
techniques" i.e. bricks and mortar or poured concrete. Almost all new industrial buildings now
use dry construction techniques. Because the work can be carried out in adverse weather
conditions and are much quicker than traditional building methods, yet every bit as durable
and permanent. Additionally they are nearly always more cost effective.
Industrialized Building System (IBS) are not a new invention to our country, Malaysia.
This system has been used almost 50 years since 1960 when Ministry of Housing and Local
Government of Malaysia visited several European countries and evaluate their housing
development program. After their successful visit in 1964, the government had started first
project on IBS aims to speed up the delivery time and built affordable and quality houses.
About 22.7 acres of land along Jalan Pekeliling, Kuala Lumpur was dedicated to the project
comprising seven blocks of 17 stories flat there are 3000 units of low-cost flat and 40 shops
lot. This project was awarded to Gammon & Larsen Nielsen using Danish System of large
panel of pre-fabricated system.
Today in the Malaysian construction industry, the use of IBS as a method of construction
is evolving. More local manufacturers have established themselves in the market. As a result
pre-cast, steel frame and other IBS were used as hybrid construction methods to build national
landmarks such as Bukit Jalil Sport Complex, LRT and Petronas Twin Tower. It was reported
that at least 21 manufactures and suppliers of IBS are actively promoting their systems in
Malaysia. IBS move to the next step of the development through the establishment of IBS
Centre at Jalan Chan Sow Lin, Cheras, Kuala Lumpur. The obligation to implement IBS serves
both to improve performance and quality in construction, as well as to minimize dependency
on unskilled foreign labour in the construction market.
1
1.1.1 Statement of problem
In this era of globalization, IBS are widely used in construction industries. Even a small
project would use IBS system which means, this kind of system may contribute a lot of
benefit to our world. This system requires skills especially when to build the component it-
self seems the construction are too difficult and heavy-duty works.
IBS takes a lot of benefit which may reduce cost in such term in every single aspect. For
example, usage of IBS would reduce the usage of workers or labours. Statistic shows that, if
constructions are using IBS system, it would cut about 65% of total cost for the labours only.
But, is the IBS system has only the benefits? How about the disadvantages? Would IBS
system give such problem and trouble to our industries? Why contractor would recommend
IBS system to our industries and what are the disadvantages while using IBS system?
2
1.2 BACKGROUND OF STUDY
Nowadays, technology becomes the greater aspect to our life. Everything in this world
involves technology and science and it’s become really crucial to humans and also a vital
aspects regarding to construction technology. What is Industrialize Building system?
Industrialize Building system (IBS) are commonly has improve our productivity and inefficiency
in construction. They are several systems in use. The most common nowadays is the steel
framed metal profile clad design. They do also use Timber buildings too, various laminates,
precast concrete, etc. These are termed dry constructions as opposed to the "wet techniques"
i.e. bricks and mortar or poured concrete. Almost all new industrial buildings now use dry
construction techniques. Because the work can be carried out in adverse weather conditions
and are much quicker than traditional building methods, yet every bit as durable and
permanent. Additionally they are nearly always more cost effective.
3
2 INDUSTRIALISED BUILDING SYSTEMS (IBS)
2.1 DEFINITION
IBS can be defines in many terms. These includes based on the different perspective and
idea they referred to. Here are some of the definitions of IBS which can be subscribed as
Industrialize building System (IBS) in our subject Construction Technology.
Albert G.H. Dietz in the book of ‘Industrialized Building Systems For Housing’ define that
Industrialized Building System as the total integration of all subsystems and components
into an overall process fully utilizing industrialized production, transportation and assembly
techniques.
According to official portal of CIDB Malaysia, Industrialized Building Systems (IBS) is

defined as the complete assembly construction which is, a construction system where
components are manufactured at factories on or off site being transported and then
assembled into a structure with minimum work. It is a technique of construction whereby
components are manufactured in a controlled environment.
An industrialized building system (IBS) also may be defined in which all building
components such as wall, floor slab, beam, column and staircase are mass produced
either in factory or at site under strict quality control and minimal on site activities (Rollet,
1986; Trikha, 1999).
Esa and Nuruddin (1998) asserted that an IBS is a continuum beginning from utilizing
craftsmen for every aspect of construction to a system that make use of manufacturing
production in order to minimize resource wastage and enhance value for end users.
Warswaski (1999) expounded that an industrialization process is an investment in

equipment, facilities, and technology with the objective of maximizing production output,
minimizing labor resource, and improving quality while a building system is defined as a set
of interconnected element that joint together to enable the designated performance of a
building.
Perhaps the most comprehensive definition of IBS was clarified by Junid (1986). He
mentioned that an IBS in the construction industry includes the industrialized process by
which components of a building are conceived, planned, fabricated, transported and
erected on site The system includes a balanced combination between the software and
hardware components. The software elements include system design, which is a complex
process of studying the requirement of the end user, market analysis, development of
standardized components, establishment of manufacturing and assembly layout and
process, allocation of resources and materials and definition of a building designer
conceptual framework. The software elements provide a prerequisite to create the
conducive environment for industrialized to expand. Meanwhile, the hardware elements are
categorized into three major groups. These include frame or post and beam system, panel
system, and box system. The framed structures are defined as those structures that carry
the loads through their beams and girders to columns and to the ground whilst in panel
4
system load are distributed through large floor and wall panels. The box systems include
that system that employ three-dimensional modules (or boxes) for fabrication of habitable
units are capable of withstand load from various directions due to their internal stability.
2.2 HISTORY CHRONOLOGY OF HOUSING
IBS in Malaysia has begun in early 1960’s when Ministry of Housing and Local
Government of Malaysia visited several European countries and evaluate their housing
development program (Thanoon et. al. 2003).
After their successful visit in 1964, the government had started first project on IBS aims to
speed up the delivery time and built affordable and quality houses. About 22.7 acres of
land along Jalan Pekeliling, Kuala Lumpur was dedicated to the project comprising seven
blocks of 17 storeys flat there are 3000 units of low-cost flat and 40 shops lot. This project
was awarded to JV Gammon and Larsen & Nielsen using Danish System of large panel of
prefabricated system. The project was completed within 27 months from 1966 to 1969
including the time taken in the construction of the RM 2.5 million casting yard at Jalan
Damansara (CIDB, 2003; CIDB, 2006 and Thanoon et al, 2003).
In 1968, the second housing project initiated by the government of Malaysia, the project
comprising a 6 block of 17 storey flat and 3 blocks of 18 storey flat at Jalan Rifle Range,
Penang. The project was awarded to Hochtief and Chee Seng using French Estoit System
(Din, 1984; CIDB, 2003 and Sarja, 1998).
Another earliest IBS project was at Taman Tun Sardon, Penang in 1978 (1,000 units of
five-storey walk up flat). IBS precast component and system in the project was designed by
British Research Establishment (BRE) for low cost housing in tropical countries.
Nonetheless, the building design was very basic and not considering the aspect of
serviceability such as the need of wet toilet and bathroom (Rahman and Omar, 2006).
Between 1981 and 1993, Perbadanan Kemajuan Negeri Selangor (PKNS) a state
government development agency acquired precast concrete technology from Praton Haus
International based on Germany to build low cost house and high cost bungalow in
Selangor (CIDB, 2003). PKNS Praton Haus Berhad that was formed in 1981 had
introduced two (2) types of construction system, large panel systems and skeleton
systems. All these large panel systems were produced in the mobile factory at Shah Alam.
In 1991, the company was fully owned by PKNS and the name was changed to PKNS
Engineering & Construction Berhad (PECB). The precast concrete and box systems have
been adopted by PECB are as follows; Tilt Up System – Australia; MyPro System –
Malaysia; O-Stable System – Malaysia (Patented by Baktian Sdn. Bhd.); HC Precast
System – Malaysia (Patented by HC Precast System Sdn. Bhd.)
Other large panel system in Malaysia include Taisei Marubeni System (Japan) which
large panel are cast in factory using tilt-up system where one panel forms the base for next
panel cast. Taisei-Setia Sdn Bhd developed 4,880 unit dwellings using this system in Shah
Alam during 1980s. The other is Ingeback System (Sweden) which is Swedish system
using large panels in vertical battery mould and tilt-up table mould. IBS was implemented in
5
Taman Maluri, Pandan Jaya and Wangsa Maju using metal-formwork system (Sarja,
1998).
Although incorporated in 1974 as a construction company, the SP Setia story really

began in 1996 when they refocused their core business to property development. Setia
Precast Sdn Bhd, a wholly owned subsidiary of SP Setia Bhd has established a firm
reputation as Malaysia’s leading IBS specialist in precast technology for high-rise
residential apartment. In the last decade, they had successfully constructed more than
10,000 units of residential apartments up to 18 stores in Ampang, Puchong, Sungai Petani
and Putrajaya (CIDB, 2006).
In 1999, the Public Works Department (PWD) had designed the 5-storey block of
quarters for Judicial and Legal Training Institute at Bangi. The first storey was built using
cast in-situ concrete beams and columns with the upper 4 storeys built with precast
concrete wall system. The precast component was supplied by Norwest Holding Sdn. Bhd.
and Associated Structural Concrete Sdn. Bhd. (CIDB, 2006).
In the year 2000 and 2004, the Finish originated company, Eastern Pretech (M) Sdn.
Bhd. had supplied prefabricated components such as hollow core slabs, precast planks,
precast balcony, precast beams, precast columns, precast staircase elements, precast
parapet walls and load bearing walls for residential projects of townhouses and apartments
at Cyberjaya and Seremban (CIDB, 2006).
Between 1998 and 2002, Encorp Berhad and Leighton introduced precast concrete walls
and precast planks in the development of 10,000 units of teachers’ quarters on 107 sites
throughout Malaysia. A total of 4,700 units of the teachers’ quarters were completed by
Sunway Precast Industries Sdn. Bhd. and the remaining units were completed by Leighton
and Hume Industries Sdn. Bhd. The project comprised low-rise (4 and 5-storey high)
apartment complexes were designed by NRY Architects Sdn. Bhd. Each apartment unit
has 3 bedrooms, 2 bathrooms, a living room, a dining room, a balcony and a courtyard
(CIDB, 2006).
In 2004, the PWD have also embarked on the new design of government quarters using
the IBS system. The Senawang Police Quarters is one of the pilot projects that employed
this new design. In this project, precast concrete wall panels were completed by Sunway
Precast Industries Sdn. Bhd. (CIDB, 2006).
Starting on 2006, O-Stable Panel Sdn. Bhd. has been widely used as IBS system in
double storey bungalow and terrace houses at Selangor and Putrajaya. The prefabricated
component was supplied for Putra Perdana Construction Sdn. Bhd. for bungalow houses at
Putrajaya, and PKNS and Baktian Sdn. Bhd. for houses in Selangor (CIDB, 2006).
Today, the use of IBS as a method of construction in Malaysia is evolving. Many private
companies in Malaysia have teamed up with foreign expert from Australia, Netherlands,
United State and Japan to offer precast solution to their project (CIDB, 2003). In addition,
131 manufactures registered with CIDB to date with 200 IBS products available in the
market (CIDB Orange Book Volume 3). Over 800 registered IBS contractor available in
2007 (CIDB Orange Book Volume 1).
6
2.3 PRINCIPLE
What is Industrialize Building system? Industrialize Building system (IBS) are commonly
has improve our productivity and inefficiency in construction. They are several systems in
use. The most common nowadays is the steel framed metal profile clad design.
Industrialized Building Systems (IBS) is defined as the complete assembly construction: a

construction system where components are manufactured at factories on or off site,
transported and then assembled into a structure with minimum work.
Any parts of structure in a building that have been manufactured in factory according to
specific approved design than transported and installed to the site.
Industrialised Building System (IBS) is defined as a construction technique in which

components are manufactured in a controlled environment (on or off site), transported,
positioned and assembled into a structure with minimal additional site work. Those parts of
building that are repetitive but difficult, time consuming, labour intense to cost at site are
design and detailed as standardised components at factory. IBS also involve onsite casting
using innovative and clean mould technologies (steel, aluminium and plastic). IBS offers
benefits in term of cost and time certainty, attaining better construction quality and
productivity, reducing risks related to occupational safety and health, alleviating issue on
skilled workers and dependency on manual foreign labour and achieving ultimate goal of
reducing overall cost of construction.
However, the availability of cheap foreign labour which offset the cost benefit of using IBS
is a root cause of the slow adoption in Malaysia. It also relates to sheer cost of investment
and the inadequacy of market size. Small contractors are already familiar with the
conventional system and for them the technology suit well with small scale projects and
therefore not willing to switch to mechanised based system. Furthermore, small contractors
lack financial backup and are not able to set up their own manufacturing plants as it
involves very intensive capital investment. As a result, the industry is reluctant to use IBS
unless it is required by the clients. A wider understanding on the characteristics and what is
involved in IBS is needed to guide the industry. There is a critical need to manage the
design and manufacturing differently from the traditional way as IBS is different and needs
a different mindset along with the right environment. Rethinking the old processes is now
critical if the industry is to move forward.
What is needed is guidance on key principals which can be orchestrated the effort to
adopt new construction mechanism. There are consensus of opinion that IBS best handled
as a holistic process rather than just a collection of technological solutions. The approach
requires total synchronisation on construction, manufacturing and design processes. It
needs emphasis on rationalisation, standardisation, repetition, collaboration, supply chain
partnering and more effective planning and project management. The article provides basis
on the principals that are critical to IBS in Malaysia which result to the success or failure on
IBS implementation. The 12 Key Principals in Implementing IBS are as follows:
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1. Changing conventional design to IBS during after the tender has been rewarded is a
bad practice. IBS can be only benefit if decision to use it can be decide as early as
possible not as afterthought during the project. The design must be firm before
manufacture and installation. The concept of design freeze should be implemented.
2. Planning is essential. IBS requires thorough arrangement of detail design, work

delivery schedule, most cost effective way for installation and logistic is coordinated
and benefit in term of shorter construction period is materialised. Tighter and longer
period of planning are required to allow for design, logistic and installation planning,
procurement and approval procedures. Extensive planning must be completed well in
advance which lead to better project performance, coordination, better scope control
and ensure smooth project sequence.
3. IBS can be best implemented if we have capability in design management and design
integration, where aspects that can benefited the projects can be incorporated through
design i.e. standardisation, modular, pre-assembly, manufacturability and
constructability.
4. Obtaining manufacturing input at an early stage of the project is essential to IBS

design. It is vital for IBS adopters to involve the project team in design stage as early
as possible to ensure their input on the issue of manufacturing, design harmonisation
and constructability are captured before the design is confirmed and transfer to the
manufacturing floor.
5. The adopters must have a clear business strategy, clear capital expenditure analysis,
structured cost control instruments and initiate the use of appropriate technology at
time. Based on the industrialisation principal, innovation adoption is an evolution which
depends on the maturity of organisation. There is no point on implementing the latest
construction technologies in IBS, without considering one capability and readiness to
embrace in it. In recent times, more and more public projects were tendered in Private
Finance Initiative (PFI) mode. Thus, requires companies to have strong finance
capability and strategy. Partnering perhaps is the way forward to build up capacity and
capability to implement IBS. Successful IBS implementation is also depends on the
strong support, commitment, awareness, vision, knowledge and leadership of
CEO/Senior Management. In most cases, IBS is a top-down implementation. Obtaining
this support could be the key to the successful IBS project.
6. IBS requires good communication channel and information flows between all level of
decision making and all project phases. Effective communication channel across the
supply chain need to be established in order to coordinate processes and deal with
critical scheduling in IBS from the beginning until the project completion. Clarity and
simplicity of communication channel is the rule. ICT could be a reliable support tool.
7. The repetition process each time project was implemented allows continues
improvement and waste elimination in the technique and processes to achieve better
performance in IBS. IBS can only benefit the adopters if the implementer can adopt
improvement in each repetitive process and potentially to cut corners in term site
arrangement, logistic, process flows due to the nature of repetitiveness. This is the
essence of manufacturing which has been adopted in construction through IBS.
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8. The imperative factor in successful IBS implementations lies in good site management,
planning and control of overall process in project life cycle. This in turn, leads to
recommendation that experience and well-trained workers are the critical for IBS.
Project Managers must be able to work with multi trade involved in IBS. Engineers with
good technical knowledge in analysis, design, manufacturing and construction have the
ability to manage systematic IBS systems. Design knowledge is also critical. If the
components are skillfully designed, erection can be carried out efficiently. Furthermore,
complying with good practices in design and construction leads to high quality IBS
structures. A comprehensive training scheme will support this.
9. IBS can only be implemented if we have demand and economy viable. IBS adopters
were suggested to be selective in choosing projects that are economic viable and can
benefit by the use of IBS. Large and repetitive contract is preferred. It was observed
that a number of successful IBS adopters are indeed a sub-division of developers
which can ensure stability, continues resources and continues business. Others initiate
partnering and strategic alliance. Only by having demand IBS can sustain.
10. ICT is the key enabler to IBS implementation and become a reliable support tool. The
application of ICT tools needs to be utilised in a more widespread manner, in order for
the IBS industry to improve efficiencies, planning, manage process and ensure
reliability of components deliveries.
11. The integration of IBS components or modules into the building requires the various
parties and supply chain to cooperate closely. This requires very careful definitions and
management of interfaces between contractors and suppliers and a good
communication channel. It has been suggested that by implementing integrated
approach in design and construction, fragmentation gap could minimised. Establishing
partnering and strategic alliance in supply chain is the way forward.
12. There is no reason why construction approach to components production should be

radically different from what is used by today’s leading manufacturers of consumer
product. It should include management and sustained improvement of the production
process to eliminate waste and ensure the right components are produced and
delivered at a right time, in the right order and without defect. In this respect Malaysian
construction industry has a great deal to learn about effective logistics management.
Industrialising construction by way of manufacture of building components and delivery

on site exactly when needed is considered an effective way to achieve productivity gains
and to make the industry more attractive for new entrance. Nonetheless, with over forty
years of laissez faire implementation in Malaysia, IBS has not widely accepted or used as
mainstream construction. To expedite the adoption of IBS, factors which are important to
IBS need to be identified. There is a critical need to manage the design and manufacturing
differently from the traditional way as IBS is different and needs a different mindset along
with the right environment. Rethinking the old processes is now critical if the industry is to
move forward. As the way forward, partnering in IBS project should be encouraged. But,
culture and competitive nature of this business will hamper partnering efforts. Government,
on the other hand should continue creating market demand for IBS particularly from private
sector. By having continues demand and volume IBS can sustain.
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2.4 WHAT IBS IS ALL ABOUT
Industrialized Building System (IBS) is a technique of construction whereby components

are manufactured in a controlled environment, either at site or off site, and transported,
positioned and assembled into construction works.
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2.5 OBJECTIVE OF IBS
To achieve the policy objective to achieve competency and productivity in terms of labor
force, the industry needs to ensure a ready pool of both professionals and workers who are
practicing IBS and reduce reliance on foreign workers
There are five main IBS groups identified in Malaysia, there are :
1) Pre-cast Concrete Framing, Panel and Box Systems – pre-cast columns, beams,
slabs, 3-D components (balconies, staircases, toilets, etc), etc;
2) Formwork Systems – tunnel forms, EPS-based forms, beams and columns

moulding forms, permanent steel formworks, etc;
3) Steel Framing Systems – steel beams and columns, portal frames, roof trusses,
etc;
4) Prefabricated Timber Framing Systems – timber frames, roof trusses, etc;
5) Block Work Systems – interlocking concrete masonry units (CMU), lightweight

concrete blocks, etc.
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2.1 CLASSIFICATION OF BUILDING SYSTEM
Based on the definition of IBS, we can conclude IBS as the complete assembly
construction which is, a construction system where components are manufactured at
factories on or off site being transported and then assembled into a structure with minimum
work. IBS is often referred as off-site construction, off-site production, industrialized and
automated construction, off-site manufacturing, prefabricated building, pre-assemblies
building, pre-cast building, pre-cast construction, non-traditional building and Modern
Method of Construction (MMC).
The classification of building system may be classified in a variety ways, depending on

the particular interest of their users or producers, also characterized by its construction
technology, functional and geometrical configuration of their main framing components.
Badir Razali (Badir et al. 1998) said basically, there are four types of building systems that
is often used in Malaysia. The building systems are namely conventional column-beam-
slab frame system with timber and plywood as formwork, cast in-situ system with steel or
aluminium as formwork, prefabricated system and the composite building system is shown
in Figure 2.0.
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Figure 1 : Type of Building System in Malaysia
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2.1.1 CONVENTIONAL CONSTRUCTION METHOD
Badir et al, (1998) stated that conventional building method is defined as components of
the building that are prefabricated on site through the processes of timber or plywood
formwork installation, steel reinforcement, and cast in-situ. Conventional buildings are mostly
built of reinforced concrete frames. The traditional construction method uses wooden
formwork. It is much more costly for construction which includes labour, raw material,
transportation and low speed of construction time.
2.1.1.1 Casts-in-situ Construction Method
According to Badir et al, (1998), this system is suitable for a country where unskilled
labour is limited. There is no heavy machinery or high technology involved. The system is
technically applicable to almost all types of building. Formwork is used as a mould where
wet concrete is poured into a temporary system. The temporary system also acts as a
temporary support for the structures. The objective of an in-situ method is to eliminate and
reduce the traditional site-based trades like traditional timber formwork, brickwork,
plastering and to reduce labour content. A carefully planned in-situ work can maximize the
productivity, speed and accuracy of pre-fabricated construction. Cast in-situ method uses
lightweight pre-fabricated formwork made of steel/fiberglass/aluminium that is easily
erected and dismantled. The steel reinforcement is placed within the formwork as they are
being erected and concrete is poured into the mould. When the concrete is set according to
the required strength, the moulds are dismantled. The workers can be easily trained to
erect the moulds and set the steel reinforcement. Its advantages over the traditional
construction method include, low skill requirement, speedy construction, lowmaintenance,
durable structure and less cost.
2.1.1.2 Composite Construction Method
Badir et al, (1998) stated that the objectives of composite construction method(partially pre-
fabricated) are to improve quality, reduce cost, and shorten construction time. The concept
of partial industrialised system is derived from the composite nature of full industrialisation,
and is used to describe a manufacturing or production strategy that selectively uses some
industrialising aspects, while avoiding or postponing the use of others. The pre-fabricated
construction method is combined in such a manner that the features applied could be
prominently demonstrated, especially composing various works such as temporary
facilities, building frames, building finishes, and equipments.
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2.1.1.3 Pre-fabricated Construction Method
In this method of construction, all elements that can be standardised are prefabricated in
the factory. Normally, this method would involve the assembly of precast elements such as
floor slabs, in-filled walls, bathrooms, staircases, etc. into place for incorporation into the
main units, columns and beams. This method of construction has reduced the amount of
site labour involved in building operations and increased the productivity of the industry.
Precast building systems can reduce the duration of a project if certain conditions are met.
The last three construction methods are considered as non conventional construction
methods. These types of construction are specifically aimed at increasing productivity and
quality of work through the use of better construction machinery, equipment, technology
and materials. In related with IBS, the prefabricated systems can be further classified into
another three categories system namely panel system, block systems, and frame systems
according to the geometrical configuration of their main framing components. In addition,
the systems also can be designed either by using timber, steel, cast-in-situ concrete or
precast concrete but usually, many construction projects in Malaysia deals with precast
concrete systems.
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2.2 CLASSIFATION OF IBS
According to Badir et al. (1998), IBS can be classified according to several aspects:
2.2.1 CONVENTIONAL CONSTRUCTION METHOD
According to Abraham Warszawski (1999), IBS system can be classified according structural
systematic aspects. IBS can be classifies into three categories as:
2.2.2 LINEAR SYSTEM OR FRAMES (BEAMS AND COLUMN)
 Frame system is system that use column and beam as the main structure member
where columns and beams support all the building weight. The walls need to be light
and easy to install and concrete panels are introduces as flooring element.
 Columns, beams, frames, or trusses made of plain or prestressed concrete is used as

their main structural elements.
 The important feature is the capacity to transfer heavy loads over large spans.
 Always used in the construction of bridges, parking lots, warehouses, industrial

buildings, sport facilities, and so on.
 Different variants of the structural scheme allow for the most convenient partitioning of
the frame into connected precast elements.
 Stability of the frames system in the longitudinal direction can be obtained by bracing
with steel diagonals, or by attaching the frame to rigid building components.
2.2.3 PANEL SYSTEM
 In panel system, loads are distributed through large floor and wall panels where walls
support the building weight.
 This system is applicable to buildings which functionally require a large number of walls
such as apartment house, hotel and hospital.
 This system is not applicable to buildings with large spans or many stories.
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 Used as structural framing also fulfill interior and exterior space enclosure functions.
 Elements for floor slabs, vertical supports, partitions, and exterior walls.
 May be prefabricated with a considerable amount of finish work.
 Reduce the content and amount of skilled labour onsite.
 It is economical use of room-size floor components.
 An aesthetic as their joints are not seen by the user.
 The stability is attained by monolithic structural elements, mostly interior cores, and by
special jointing provisions, prescribed by the structural codes.
 The dimensions of panel components are determined by their support system, the layout
of enclosed spaces, and other architectural design features.
Figure 2 : Frame System
Figure 3 : Panel System

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2.2.4 RECTANGULAR OR BOXES SYSTEM OR TRHEE DIMENSIONAL

SYSTEM
 The box systems include those systems that employ three-dimensional modules or
boxes for fabrication of habitable units that are capable of withstanding load from
various directions due to their internal stability.
 As their main building element; box units that contain concrete walls and floors either
cast in boxlike molds or assembled in plant from panel elements.
 Can contain substantial amount of finish works; which are made in the plant before
shipping the module to erection site.
 The size is determined by transportation and erection considerations.
 It can contain more finish works than other prefabricated forms.
 A maximum saving of human labour onsite.
 Less flexible than panel and frame elements, which can be used in almost any
architectural layout with relatively minor adaptations.
 Their considerable weight and bulkiness involved transportation and erection and it is
a costly process.
 The use of block system in excess of three or four stories requires special structural
adaptations.
Figure 4 : Box System
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2.3 CLASSIFICATION ACCORDING TO MATERIAL
2.3.1 TIMBER
There are two types of prefabrication of timber which is ready-cut plus shop fabrication of
joints (column and beam) and structural panels where there are only walls and floors without
column and beam.
2.3.2 BRICK AND BLOCK WORK
Laying of brick or block are carried out in a mass at factory and transported to site or on
site beside the building under construction in the form of panel and then erected.
2.3.3 STEEL
Steel construction essentially contains factors of prefabrication which is one of thecriteria

of IBS. Elements are jointed by welding, riveting or bolting on site. The largeproportion of the
strength to the weight allows a long-span or high-rise building.
2.3.4 REINFORCED CONCRETE
Reinforced concrete has high degree of availability, low material cost, durability, and fire
resistance. There are two basic directions in development of reinforced concrete.
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2.4 CLASSIFICATION ACCORDING TO RELATIVE WEIGHT OF

COMPONENTS
The IBS components can be classified according to their relative weight as in Table
2.4.Majzub (1977) mentioned that the relative weight of components should be used as a
basis for building classification due to the factor of weight has significant impact on the
transportability of components and has influence on the production method of the components
and their erection method on site.
Table 1 : Building System Classification According to Relative Weight of Component
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2.5 FIVE MAJOR GROUPS OF IBS
According to CIDB (2001), the Industrialised Building System is a construction process that
utilizes techniques, products, components, or building systems which involve prefabricated
components and on site installation. Base on the structural aspects of the system, IBS can be
identified into five major groups:
2.5.1 PRECAST CONCRETE FRAMING, PANEL AND BOX SYSTEM
Precast concrete elements are the most common IBS type. In addition, there are precast
concrete columns, beams, slabs, walls, lightweight precast concrete, and permanent
concrete formworks. Besides that, it is also consist of 3D components such as balconies,
staircases, toilets, lift chamber, refuse chambers and etc.
2.5.2 STEEL FORMWORK SYSTEMS
There are two types of popular formworks which are known as wall formwork and the
other is called as tunnel formwork. They generally involve site casting, and therefore
subjected to structural quality control. So, it is considered as the “low level” or the “least
prefabrication” IBS types. However, this system does offer high quality finishes and fast
construction with less site labor and material requirement. These include tunnel forms, tilt-up
systems, beam and columns moulding forms and permanent steel formworks like metal
decks.
2.5.3 STEEL FRAMING SYSTEMS
This type of IBS is usually refers to a building technique with a "skeleton frame" of vertical
steel columns and horizontal I-beams, which is constructed in a rectangular grid functioned
to support the floors, roof and walls of a building which are all attached to the frame. This
system commonly used with precast concrete slabs, steel columns and beams have always
been the popular choice and used extensively in the fast-track construction of skyscrapers.
Recent development in this type of IBS includes the increased usage of light steel trusses. It
is consisting of cost-effective profiled cold-formed channels and steel portal frame systems
as alternatives to the heavier traditional hot-rolled sections.
2.5.4 TIMBER FRAMING SYSTEMS
There are two types of timber frame structure which known as frame wall construction
and timber frame construction. This timber frame construction is based on timber members
and components which form a structural frame and transmits all the vertical and horizontal
loads to the foundations and normally is timber building frames and timber roof trusses.While
timber roof truss systems are more popular, timber building frame systems also have its own
niche market where it is offering interesting designs from simple dwelling units to buildings
requiring high aesthetical values such as chalets for resorts.
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2.5.5 BLOCKWORK SYSTEMS
The block work system is used as load bearing wall and can carried the load as it
designed. In spite of this, the block work system is varied in types of shapes and it is more
effectively compared to others but in the other side, the cost is higher. By using this effective
alternative system, the tedious and time-consuming traditional brick laying tasks are greatly
simplified. The construction method of using conventional bricks has been revolutionized by
the development and usage of interlocking concrete masonry units (CMU) and lightweight
concrete blocks.
Based on the five major groups of IBS, the construction industries in Malaysia commonly
used the precast concrete system as the construction based on IBS. It is clearly stated
above that the precast concrete system is classified into another three categorizes which is
known as frame, panel and box system.
Figure 5 : Examples of Linear Systems for Industrialised

Buildings
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Figure 6 : Typical Linear Prefabricated Elements
23
Figure 7 : Typical Schemes of Industrial Linear
24
Figure 8 : Different System of Planar System
Figure 9 : Precast Floor Elements
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Figure 10 : A Generic Precast Concrete Framed Building
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2.6 SYSTEM OF IBS
2.6.1 CLOSED SYSTEM
Closed system is a system where all elements of industrial production of components to

be used for specific designs for specific projects. The system does not allow for the
interchangeability of components from different factories.
A closed system can be classified into two different categories, namely production based
on client’s design and production based on precaster’s design. The first category is designed
to meet a spatial requirement of the client’s, that is the spaces required for various functions
in the building as well as the specific architectural design. In this instance, the client’s needs
are paramount and the precaster is always forced to produce a specific component for a
building. On the other hand, the production based on precaster’s design includes designing
and producing a uniform type of building or a group of building variants, which can be
produced with a common assortments of component. Such building includes school, parking
garage, gas station, low cost housing, etc. Nevertheless these types of building arrangement
can be justified economically only when the following circumstances are observed.
a) The size of project is large enough to allow for distribution of design and production
costs over the extra cost per component incur due to the specific design.
b) The architectural design observes large repetitive element and standardization. In

respect to this, a novel prefabrication system can overcome the requirement of many
standardised elements by automating the design and production process.
c) There is a sufficient demand for a typical type of building such as school so that a mass
production can be obtained.
d) There is an intensive marketing strategy by precaster to enlighten the clients and designer
the potential benefit of the system in term of economics and noneconomic aspects.
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2.6.2 OPEN SYSTEM
Open system is a system which allows the production of building components by various
factories and to be compatible with each other to be used in any building project. The
successful implementation of open industrialization building system requires a modular
coordination.
In view of the limitations inherent in the closed system, an open system which allows
greater flexibility of design and maximum coordination between the designer and precaster
has been proposed. This system is plausible because it allow the precaster to produce a
limited number of elements with a predetermined range of product and at the same time
maintaining architectural aesthetic value.
In spite of many advantages inherent in an open system, its adoption experiences one
major setback. For example, joint and connection problem occur when two elements from
different system are fixed together. This is because similar connection technology must
be observed in order to achieve greater structural performance.
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2.7 MODULAR COORDINATION IN IBS
Modular Coordination is a concept of coordination of dimensions and space where buildings

and components are dimensioned and positioned in a basic unit or module known as 1M
which is equivalent to 100 mm, as stipulated in MS 1064, and developed in 2000. MS 1064 is
a guide line towards the usage of Modular Coordination (MC) in building constructions which
consists of Part 1 to Part 10 under the general title, "Guide to Modular Construction in
Buildings". It provides the general principles, room and storey heights, coordinating sizes and
preferred sizes for various building components, dimensions of elements, components and
spaces in the planning and design of building.
The use of Modular Coordination is an important factor in IBS effective application as it

completes the industry through quality control and increase of productivity and constructability.
The concept allows standardization in design and building components. It encourages
participation from manufactures and assemblers to enter open system market, thus reducing
the price of IBS components. With open system approach, building components could
combine in a variety of individual building projects while ensuring the architect freedom in their
designs. In essence, Modular Coordination will facilitate open industrialisation. The
characteristic of Modular Coordination are:
 The basic module is small in terms of odd size in order to provide design flexibility, yet
large enough to promote simplification in the components' variation in sizes.
 Industry friendly features that not only cater for manufacturing but also the transportation
and assembly requirements.
 Ergonomically designed to promote efficiency
 Internationally accepted to support international market
Modular Coordination is essentially based on:
 The used of modules (basic modules and multi-modules)
 A reference system to define coordinating spaces and zones for building elements and
for the components which form them
 Rules for locating building elements within the reference system
 Rules for sizing building components in order to determine their work size
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 Rules for defining preferred sizes for building components and coordinating dimensions
for building.
The proposed enforcement of using Modular Coordination through Uniform Building By-
Laws (UBBL) would encourage open system in IBS. The propose force Modular Coordination
in UBBL is yet to be taken onboard due to readiness of our architect and/or ignorant of them
towards change. The issue of Modular Coordination arose when we convert from British
measurement to SI. Instead of 1 yard we use mm.
The disadvantage of SI, it is difficult for manufacturer to produce components based on

mm tolerance. Can you imagine the length of the beam is 2033 mm? So, it is easier for
manufacturer to standardize it into 20M instead. This standardisation make easier for open
system where everybody can produce the component based on modular. Modular
Coordination has been introduced in Malaysia since 1986, but has not been widely
implemented in the building industry. The main factors limiting the uses of Modular
Coordination in building industries is lack of knowledge on Modular Coordination concept and
it requires precision dimensioning and proper planning. Modular Coordination may be applied
to the design, manufacture and assembly of buildings, its components and installations. It also
affects the work positioning and dimensioning during construction. At the work level, Modular
Coordination allows for relative independence in decision making with the common
dimensional language. MS 1064 (Guidance to Modular Coordination In Buildings) contains 10
parts and based on the ISO standard that is recognized internationally.
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2.7.1 BENEFIT IMPLEMENTING MODULAR COORDINATION
1. Facilitates cooperation between building designers, manufacturers, distributors,

contractors and authorities.
2. In the design work, enables buildings to be so dimensioned that they can be erected with
standard components without undue restriction on freedom of design.
3. Permits a flexible type of standardization, which encourages the use of a limited number
of standardized building components for the construction of different types of buildings.
4. Optimizes the number of standard sizes of building components.
5. Encourages as far as possible the interchange ability of components, in whatever

materials, forms or methods of manufacture.
6. Simplifies site operations by rationalizing setting out, positioning and assembly of

building components.
7. Ensures dimensional coordination between installation (equipment, storage units, other

fitted furniture, etc.) as well as with the rest of the building.
2.7.2 BENEFIT IMPLEMENTING MODULAR COORDINATION
2.7.2.1 The use of modular

a. basic module
1 m = 1000mm
b. multimodal’s
3 m, 6 m, 9m, 12m, etc (example: piles)
c. sub modules
m/2, m2/4
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2.7.2.2 A reference system to define coordinating spaces and zones for building
elements and assemblies
a. basic modular grid for small scale drawings to clarity relationship between
components
b. superimposed grid
Used in key plans, showing layout and positioning of main building components
c. displacement of grids
Band of interruption are regulary spaced in both directions.
d. interrupted grid
To accommodate certain element
2.7.2.3 Rules for locating building elements within reference system
a. type of references
Modular reference system enable designer to relate sensibly elements of

construction envelope, horizontal and vertical elements.
2.7.2.4 Rules for sizing of building components
a. coordinating size = work size + one joint
b. work size : manufactured size
c. joints : components joints
2.7.2.5 Rules defining preferred size for building components and coordinating
dimensions for those building
a. Preferred sizes to rationalize the prefabrication process and to keep cost down.
b. Preferred size limits variations.
c. Selection of preferred size
~ Function
~ Construction method
~ Material of components
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2.8 MATERIAL AND COMPONENT
2.8.1 MATERIAL
Development in prefabrication and industrialization in construction have been matched by

improvements in materials and methods, along with the introduction of entirely new
materials. Advances range from the modest the exotic.
Cement is one of the most common materials in prefabricated panel and box system.
New types of cement, such as controlled-set and expansive cement, have led to improved
method of controlling quality and preventing shrinkage and cracking during curing. Additives,
used to shorten curing time and to control setting in varying temperature conditions, have
also improved control of production and scheduling. Experimental cements, possessing the
ability of self-pre-stressing by controlled shrinkage, have been tested in projects and promise
to simplify pre-stressing and/or post-tensioning by eliminating the need for the special
equipment currently used to induce tension mechanically.
Industrialization, as related to concrete, may be divide into five basic categories:
a) Precast open structural component, such as T, double –T, U, H, and L sections,

delivered to the site from the factory or precast on site. To increase span, and to reduce
the depth and area of given section, post- or pre-tensioning methods of reinforcement
may be used.
b) Vertical structural elements of various designs and sizes. Basically, these may be
divided into single-story and multi-storeys types, and may be combined with precast
elements of category.
c) Precast façade elements of various designs, either seated on or suspended from

the structural frame, which may be fabricated from reinforced concrete or steel. The use
of such elements is often predicated on aesthetic rather than utilitarian considerations,
and thus they are usually rather heavy, increasing the load on the structure, while their
structural potential remains unused.
d) Prefabricated, reinforced-concrete closed panel and box (volumetric) system,

where large space –enclosing elements may be produced either on or off site for large-
volume projects, usually housing.
e) Miscellaneous precast elements, such as culverts, pipes, lintels, road curbs,

dividing strip elements and fence posts.
Steel technology has also made considerable progress in producing new varieties of
high-strength, as well as highly ductile, steel including the change from riveting to bolting by
means of high-stress bolts. More efficient welding methods in the shop allow for higher
33
quality, and more economical method, of prefabrication off site and for development of light-
weight skeleton systems for various building system. Costume scent paints and sprayed-on
fireproofing have made steel compatible with concrete system where high fire resistance is
required.
Steel, with the ability to develop seld-sealing rust surface, have led to new design solution
for exterior. New design for space frame, staggered trusses and cable-supported structure,
usually prefabricated off site and assembled without waste on site, have made it possible to
cover vast spaces for spectator events. Example include football stadia and Olympic sport
facilities.
Modern industrialized metal system may be classified as follows:
a) Industrialized structural components (usually steel), other than conventional

standard steel sections, post and beam systems, and space frames.
b) Covering systems for facades, interiors, roofs, overhangs and other

miscellaneous cladding purpose. These may be flat panels or formed elements made of
steel, aluminium or composite (sandwich) construction with other materials. The range of
finished is considerable (painted, sprayed, anodized, enamelled, and galvanized).
c) Combination of (a) and (b), comprising open components, kits of part and fully
coordinated (closed) functional package for various building types.
2.8.2 COMPONENT
There are some of the fundamental elements of industrialized building system (IBS) that
have been made, first is floor components work out well with the subflooring applied and this
method has been thoroughly tested in thousands of house. Second is wall components
should be of room size, and in some cases longer. The dry-wall material must be applied to
both sides of the wall in the shop and should be glued as well as stapled. Third is ceiling
should be 8’ wide and room depth. All joists should be strapped to provide a better surface
for the drywall, permit the electric wiring to be pulled across the ceiling under them, and let
us out any water that might accumulate if it should storm before the roof is on. Fourth is roof
components should be up to 8’ in width, and rafter length. And the last one is gable
components work better if built in single units, and should be so designed that studs may be
square-cut instead of having to be cut to the roof pitch. This helps to use up short length.
34
2.9 TYPES OF CONNECTION
2.9.1 PINNED CONNECTION
 Pinned connections transfer purely shear forces, both for gravity and uplifting forces.
 The connections lend themselves to simple detailing and construction, and may be
formed in the simplest manner by element to element bearing.
 The connection is completed by surrounding the steel inserts with connections grout for
fire and durability protection.
 Pinned connections occur mainly where vertical and horizontal elements are joined.
 Advantages of pinned connections:
 Simple detailing
 Easy to construct
 The simples pinned can be formed by element to element bearing
 To stabilize frame with pinned connections:
 Provide bracing system such precast concrete shear walls.
Figure 11 : Comparison between Unstable Frame and Stable Frame
35
 Pinned connection with steel inserts are used to:
 Increase bearing capacity
 Reduce localized spalling
Figure 12 : Pinned Connection with Steel Inserts
Figure 13 : Plates or Steel Sections are anchored

into the Components
36
Figure 14 : Example of Pinned Connection
37
2.9.2 MOMENT RESISTING CONNECTION
 These connections are used mainly to:
 Stabilize and to increase the stiffness of portal and skeletal frames
 Reduce the depth of flexural frame members
 Distribute second order moments into beams and slabs, and hence reduce
column moments
 Improve resistance to progressive collapse
2.9.3 RIGID CONNECTIONS
 Rigid beam-to-column connection is formed by overlapping steel bars and in-situ

concrete.
 Connection is made at point zero moment.
 Simple connections at inflection points are possible.
 Rigid connections between column-to-base can be of three types:
 Pocket foundation
 Base plate connection
 Grouted sleeve
38
Figure 15 : Example of Rigid

Connection
Figure 16 : Rigid Beam-to-column Connection
39
Figure 17 : Rigid Beam-to-column Connection
40
2.10 STRUCTURAL MEMBER CONNECTION
2.10.1 COLUMN CONNECTIONS
 The main principle involved in making column connections is to ensure continuity and
this can be achieved by a variety of methods.
 In simple connections a direct bearing and grouted dowel joint can be used, the dowel
being positioned in the upper or lower column.
 Where continuity of reinforcement is required the reinforcement from both upper and
lower columns left exposed and either lapped or welded together before completing
the connection with in-situ concrete.
 A more complex method is to use a stud and plate connection where one set of
threaded bars are connected through a steel plate welded to a set of bars projecting
from the lower column; again the connection is completed with in-situ concrete.
 Typical column connections are shown in the beam connections, a common

dimension being 600mm above structural floor level.
 The columns can be of single or multi-storey height, the latter provisions for beam
connections at the intermediate floor levels.
2.10.2 COLUMN TO BASE CONNECTIONS
 The footing to column connection typically takes the form of dowels bars projecting
from the footing with matching cast in grout tubes in base of the column.
 This allows the column to be lowered directly over the dowels onto preset levelling
shims.
 The dowels act firstly as locating pins, and secondly, as a pin joint when the grout
tubes and base are fully grouted.
 Grouted pocket and base plate are most commonly used.
 The base plate has the advantage that the column may be stabilized and plumbed
vertical by adjusting the level of the nuts to the holding down bolts.
41
 This is particularly important when working in soft ground conditions where temporary
propping may not provide adequate stability alone.
2.10.3 COLUMN TO BEAM CONNECTIONS
 The column to beam connection is usually made up dowels projecting from the top of
the column over which the beam, again with matching grout tubes, can be lowered
directly onto preset levelling shims on the column.
 As there is likelihood that the beam, either during erection or in service may be subject
to uneven loading a course threat bar (such as a Reid Bar) is used as the dowels.
 This threaded bar then allows the use of nuts and washers to clamp the beam to the
column and in the most cases eliminate the need for propping of the beam.
 By using this type of connection the dowel can be projected above the top of the beam
to enable the next level of column to be erected in a similar fashion to the footing to
column connection.
 The grout tubes used for the connections are kept reasonably large (typically 50mm
diameter) to allow the use of high flow grout rather than requiring pressure grouting.
2.10.4 CONNECTIONS OF HOLLOW CORE SLAB
 These are provided between the edges of the hollow core floor units and beams or
walls running parallel with the floor.
 Their main function is to transfer horizontal shear, generated in the floor plate by
diaphragm action.
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2.10.5 FOUNDATION CONNECTIONS
 Precast columns are connected to their foundations by one of two methods,

depending mainly upon the magnitude of the load.
 For light and medium loads the foot of the column can be placed in a pocket left in the
foundation.
 The column can be plumbed and positioned by fixing a collar around its perimeter and
temporarily supporting the column from this collar by using raking adjustable props.
 Wedges can be used to give added rigidity whilst the column is being grouted into the
pocket.
 The alternative method is to cast or weld on a base plate to the foot of the column and
use holding down bolts to secure the column to its foundation in the same manner as
described in detail for structural steel work.
2.10.6 BEAM CONNECTIONS
As with columns, the main emphasis is on continuity within the joint. Three basic methods
are used:
 A projecting concrete haunch is cast on to the column with a locating dowel or stud
bolt to fix the beam.
 A projecting metal corbel is fixed to the column and the beam is bolted to the corbel.
 Column and beam reinforcement, generally in the form of hooks, are left exposed. The
two members are hooked together and covered with in-situ concrete to complete the
joint.
43
3 INSTALLATION OF PRECAST INDUSTRIALISED

BUILDING SYSTEMS (IBS)
3.1 INSTALLATION
Procedure for the Proper Installation of Precast Wall Panels, Double Tees, Beams, Columns
3.1.1 SHIPPING NOTIFICATION
A. Please provide minimum of 7 working days’ notice prior to site procurements.
B. Place order by piece mark number and required sequence of installation.
C. The piece mark number is located on the end of the precast component.
D. Prior to placement of order verify that the erection drawings in your possession are
current and up-to-date by contacting your project coordinator.
E. Actual shipping dates are subject to availability of trailers, weather and prior shipping
commitments.
F. Supply transportation manager with written direction to jobsite.
3.1.2 BEFORE ORDERING
A. Bearing requirement and erection details to be as per drawings and details.
B. Verify all site dimensions and conditions shown on drawings and details prior to
ordering of precast components to ensure proper fit. All corrections or field
modifications are to be completed prior to placing order.
C. Written approval shall be obtained from the engineer of record prior to erection of the
precast components for stability of the supporting structure.
D. Ensure all material necessary for the erection of precast components is on hand and
properly located as per drawing and details, as well as per structural & architectural
drawings.
44
3.1.3 TRANSPORTATION
A. Loads may be governed by legal trailer and/or geometry.
Sequence of slabs for off-loading may differ slightly from that ordered due to slab
geometry and load optimization.
B. Tie down and minimum 4” wide dunnage to be aligned vertically.
C. Placement of dunnage will be shown on handling diagrams.
D. Moving the load without proper tie-down may cause damage to the precast
components.
E. Inspect precast components prior to off-loading for any damage and report it
immediately to the project manager. Otherwise, it is understood that the product arrived
to the jobsite damage free. Any damage to the product during installation will be the
responsibility of others.
F. Suitable access shall be provided by maintained to and from the trailer staging area.
3.1.4 SITE STORAGE
If required, site storage of precast components shall be conform to the following

requirements:
A. Storage area to be firm, level and true.
B. Bottom precast components to be blocked minimum 4” above grade, full length and
width, as to prevent settlement of precast stack.
C. No other load on top of the precast stack is allowed unless written approval from
engineering is obtained.
D. Always handle double tees and beams in the flat horizontal position. Never turn
component on edge or end unless approved by engineer.
E. Placement of dunnage will be shown on handling diagrams.
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3.1.5 HOISTING
A. Use lifting gear of adequate capacity with minimum safety factors of 5:1. Inspect gear at
least daily for signs of wear and/or damage. Installer to verify safe working capacities of
ring clutches, sling and/or spreaded bars prior to use. Never lift more than rated
capacity.
B. Only use equipment specifically suited for the erection of precast concrete. Never handle
precast from the middle of the component.
C. Only one precast component to be hoisted at a time.
D. Ensure load is balanced to avoid slipping and to minimize twist on lifting gear and
precast component. Precast to be handled level and true at all times.
E. Do not use precast component as a platform for hoisting other building materials unless
a procedure is submitted by the engineer.
F. Never handle the precast components on its side. Only on top surface or by lifting gear.
Never put hands on side of components. Keep hands on top all times.
G. Do not tilt product as to bear loads onto product below.
3.1.6 PLACEMENT
A. Precast components to be located as per drawing. When applicable, refer to drawings to

determine minimum bearing requirement. Bearing less than shown to be approved by
engineer.
B. Drawings are to be read in conjunction with architectural and structural drawings for
connection details of other building components and/or structural systems interfacing
with precast components.
C. All hangers, clips, ties, supports, etc necessary are to be located as per drawings and
details as well as architectural/structural drawings.
D. Any deviation shall be reported immediately to engineer.
E. Erect precast components with piece mark at end indicate on drawings and at end of
precast components.
46
F. The design, installation and inspection of all temporary bracing and shoring shall be the
responsibility of the installer’s engineer.
G. The installer is responsible for ensuring all precast components are properly aligned and
levelled to within allowable tolerances.
H. Precast installation to structural steel shall be reviewed by the engineer of record with
respect to unbalanced loading of same.
I. If precast is being use for bracing, the structure is not assume to be in a final braced
condition until all precast is connected in accordance with drawings.
3.1.7 FIELD REPAIRS AND MODIFICATION
A. If precast is damaged, or requires modifications to suit site conditions, contact the

engineering immediately.
B. Repair or rework procedures are to be reviewed by engineering prior to implementation.
C. Prior to any cutting or coring, contact the engineer.
If have any damaged product, improper fit, field modification required, question about the
drawing call the project manager or project coordinator.
3.2 CONSTRUCTION SEQUENCE OF PRECAST CONCRETE

STRUCTURES
1. Site preparation
Mechanical, electrical and plumbing (MEP) trenches were excavated. MEP trench precast
concrete modules were placed. MEP outlets were prepared for the module connections.
2. Pouring of the cast-in-place ground floor slab.
This slab also functioned as the mat foundation of the project. Column and stair tower
foundations were poured separately due to their higher load intensity than other areas. All
embedded hardware was installed at the desired locations during this stage.
47
3. Precast concrete columns and load-bearing walls were erected with temporary bracing.
The bracing would be removed after all pieces were in place. The columns were
connected to the foundation with base plates and mechanical couplers. The wall panels
were connected with steel plates. Both types of connections were grouted to transfer
compression and to protect the connections from the element.
4. The inverted tee beams were installed on the columns.
Concrete corbels were cast integrally with the columns to support the inverted tee beams.
Top connections were supplied to prevent the inverted tee beams from rotation due to
unbalanced load from double tees.
5. Floor members such as double tees, flat slabs and hollow cores were erected.
They were supported by the continuous ledges on the inverted tee beams or the load-
bearing walls. Concrete topping and finishing are then placed.
6. The required room modules of the ground floor were installed on the ground floor slab.
The modules were connected to the ground floor by dowels and grout.
7. The corridor slabs were erected between the room modules.
The slabs would be supported on their longer sides on the notches of the room modules.
8. Once the construction of the ground floor was complete, the upper level room modules
were erected over the ground floor modules.
They were connected together by dowels and grout. The upper modules would also fix
the corridor slabs in place.
9. Steps 7 and 8 were repeated up to the desired level (Figure 19).
10. The stair towers and elevators towers were constructed along with the room modules.
They would also be the module construction to reduce the construction time.
11. Top roof slabs were installed between the top-level room modules.
12. Roof parapets and other architectural panels were erected.
They are not critical for the strength of the building so decorative finishes and textures
could be employed extensively.
13. Roof insulation and toppings were placed.
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14. Finishing.
3.3 ADVANTAGES AND DISADVANTAGES OF IBS
3.3.1 ADVANTAGES
The benefits of IBS system can be clearly divided into 4 main categories which are:
1. Cost
 Requirement of few on-site workers significantly reducing labour cost for

contractors (installers).
 Minimum material waste through quality control and continuous improvement.
 Sustainability as component moulds could be used repeatedly for different

projects, allowing economic of scale and reduction in amortisation cost.
 Exemption of the Construction Levy on residential developments with at least

50% of IBS content.
2. Quality
 As most components are manufactured in the factory, the quality, or rather high
quality can be consistent and maintained. The wall surfaces, the soffit surfaces
and so on can be controlled right to the millimetres in dimensions, hence
improved and consistent quality.
 Eliminate substandard product through ‘zero-defect’ programme.
 Skilled workers with specific scope of works improve efficiencies and reduce
errors.
49
3. Time
 Faster completion of projects due to advance off-site preparations and efficient

installations.
 Manageable construction schedule by the use of planning control, estimated lead

time and forecasted down time.
 Not affected by weather element as off-site production allows 24-hours operation.
4. Safety
 Promote safe and systematic factory working environment.
 Safer working environment as minimal work is required on-site.
 Cleaner sites due to timely material delivery, systematic components storage,

reduction of construction material and waste on-site.
3.3.2 DISADVANTAGES
Whereas, the backsides of IBS system are:
1. In most cases, there is a high initial capital costs for the contractors which might decide
to transfer the costs to the buyers. Plus, with only a handful of IBS players in the country,
there is quite a 'monopoly' system.
2. Difficulties in transportation also will lead to a problem of using IBS systems. As the
components may come in a very big size or panel, so that a special transport may
require for carrying it to the site. The difficulties also may arise when the distance of the
site is far away from the factory.
3. Further to that, the standardization of building components and elements also results in
a lack of aesthetics value. Buildings tend to be very boxy and square-y, which may not
look as impressive as the conventional curvy buildings. But this part here, IBS systems
are being expanded to be more architecturally and eye-pleasing.
4. Another major problem is when the contractors have bad workmanship while using pre-
fabricated panels. This can result in problems in the joints thus resulting in water
leakages. In a country like Malaysia where it rains practically every day, the problem can
be very severe. To counter this problem, one has to thoroughly check through the
completed units during handover to make sure the developer sorts out these defects.
50
5. Another disadvantage with pre-cast elements is that these components are considered
to be inflexible, with respect to changes/renovations. Most people would want to drill
holes for wall lamps and so on - which is okay. But for some, they want to hack to allow
for additional conduit works and wiring works - which might be a hindrance. If one buys
two adjoining units, they may have problems trying to hack down some walls to allow
two units to breakthrough.
3.4 COMPARISON BETWEEN SYSTEM IBS AND

CONVENTIONAL METHOD
Industrialised building system has the following benefits when compared to the conventional
construction method.
a) The repetitive use of system formwork made up steel, aluminium, etc and
scaffolding provides considerable cost savings (Bing et al. 2001).
b) Construction operation is not affected by adverse weather condition because

prefabricated component is done in a factory controlled environment (Peng,
1986).
c) Prefabrication takes place at a centralised factory, thus reducing labour

requirement at site. This is true especially when high degree of mechanisation
involved (Warszawski, 1999).
d) An industrialised building system allows for faster construction time because

casting of precast element at factory and foundation work at site can occur
simultaneously. This provides earlier occupation of the building, thus reducing
interest payment or capital outlays (Peng, 1986).
e) An industrialised building system allows flexibility in architectural design in order

to minimise the monotony of repetitive facades (Warszawski, 1999).
f) An industrialised building system provides flexibility in the design of precast

element as well as in construction so that different systems may produce
their own unique prefabrication construction methods (Zaini, 2000).
g) An industrialised building system component produces higher quality of

components attainable through careful selection of materials, use of
advanced technology and strict quality assurance control (Din, 1984).
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3.5 BARRIERS TO THE ADOPTION OF IBS IN MALAYSIA
A survey undertaken by CIDB in 2003 found that only mere 15% used IBS in the local
construction industry. The reasons of slow adoption of IBS in Malaysia are:
i) Inconsistent of houses demand, high interest rate and cheap labour cost make
it hard to justify large capital investment and it is easier to lay off workers during
slack period.
ii) A high degree of precision is required in fully prefabricated construction system

while Malaysia still lack of skilled workers.
iii) Too many parties involve in construction industries. The owners, contractors
and engineers still lack of scientific information about the economic benefits of
IBS. This makes the agreement on the utilisation of IBS during planning stage
difficult to be achieved.
iv) Majority of IBS in Malaysia are imported from developed countries and thus
drive up the cost.
v) The economic benefits of IBS are not well documented in Malaysia.
vi) Most of projects constructed with IBS in Malaysia were low quality and high
construction cost. Utilisation of IBS in Japan and Sweden are so successful due
to projects constructed with IBS are high quality and high productivity.
vii) Many architects and engineers still unaware of the basis element of IBS such as
modular co-ordination.
52
3.6 METHODOLOGY
Figure 18: Methodology of IBS

53
4 CASE STUDY
54
4.1 COMPANY PROFILE
Currently, TCS is one of the leading installers of concrete products in Industrialized Building
System (IBS) industry. As its growing popularity in private sectors and the commitments of
the Malaysian government to phase out high dependency of foreign workers, the IBS has its
huge potential to be a high growth segment of the civil construction and engineering
industries.
The Business of Teraju Construction Sdn Bhd. (TCS) was started on 5th
March 2008. Since its first inception a year ago as a sole proprietor status led by Mr
Fakhrul Nazhi Hannafi, the business known as Teraju Precast Enterprise (001748433-U) has
grown tremendously particularly in sync with the call of the Malaysian government in
2008 for a greater use of Industrialized Building System (IBS) in its development
projects. By 2nd Mac, 2009, with the spirit of moving the business to the next level, it was
converted into a limited company status by the name of Teraju Construction Sdn. Bhd.
(656680-D) 3 million with the total value of secured projects to date worth RM3 million for the
next 6 months.
Our commitment is to meet our clients‘higher satisfaction through our practical technical
solutions, competitive costs and fast tract schedule. Our tract record includes several sizable
and prestigious projects. All have been implemented in record time with high quality and to
our clients’ complete satisfaction.
55
4.2 VISION
“To Become an Expert and a Leader in IBS Construction Solution”
4.3 MISSION
- The broad mission of Teraju Construction Sdn. Bhd. Is to achieve the formulated vision
through the following strategies
- To hire, retain and develop the right people in order to continue the drive and the tenacity
to become an expert and a leader in the industry.
- To develop and deploy the right processes in order to achieve sustainable overall
organizational effectiveness.
- To use the right technology in order to achieve target rate of productivity and thus build
long term competitive advantage.
4.4 COMPANY MOTTO
“Your Reliable IBS Solution Provider”
56
4.5 QUALITY POLICY STATEMENT
To meet customers satisfaction through continuous process improvement and human

resources development
TCSB’s Quality Policy is supported by the following objectives
- To operate within ISO 9001 : 2008 Quality Management standards
- To provide services to our customers so as to enable them to operate at optimum

level through minimisation of cost, maximisation of revenue and attainment of
best quality result to ensure continuous profitability and growth.
- To upgrade, enhance and provide opportunities for development and growth for
all levels of personnel to consistently meet customer requirements in our strive to
gain customer satisfaction.
- To continuously improve, create, innovate and enhance work system / methods in

order to optimise utilisation of resources.
57
4.6 ORGANIZATION CHART
Board of Directors
Fakhrul Nazhi Hanaffi
Dr Muslim Har Sani
Mohamad
Managing Director
Fakhrul Nazhi Hanaffi
Finance & Admin

Farah Wahida
Contract Division Project Manager (Precast) Othman
Mohd Zahiruddin Razali Azman Abdullah
Assistant
Accountant
Engineer
Engineer (In‐situ)
(Precast)
Mohd Najmudin
Mohamad Zharif
Supervisor
Site Agent Supervisor
Zaihan
Mohd Firdaus Rizzuan Hj Daud
Kamaludin
58
4.7 PROJECT PROFILE
59
Project Name : Cadangan membina dan menyiapkan sebuah Sekolah Kebangsaan Taman
Bukit Dahlia yang mengandungi 24 bilik darjah dan kemudahan berkaitan.
Address : Lot (PTD) 155628 ,Mukim Plentong, Daerah Pasir Gudang, Negeri Johor darul
Takzim.
Client : Kementerian Pelajaran Malaysia, Pusat Pentadbiran Kerajaan Persekutuan 02070

Putrajaya
Quantity Surveyor : Jurukur Bahan Utama
Total block : 5 blocks 3 storeys ( 1 pre-school, 1 TNB )
Area : 23763 m2
Construction Duration : 1 December 2011 – 28 February 2013
Estimated Project Cost : RM 14.5 million
60
4.8 THE PRECAST CONCRETE COMPONENT USED BY THE

PROJECT
1. Precast concrete column

 Length x width = 400 x 400
Figure 19 : Drawing of column
column
Figure 20 : column
61
2. Precast concrete beam

 Length x width = 200 x 200
400 x 400
Figure 21 : Drawing of beam
Figure 22 : Beam at site

Figure 23 : Beam
62
3. Precast concrete slab

 Thicknesses = 275mm
 Length = 3930mm
 Width = 1200mm
Figure 24 : view of slab
Width
Figure 25 : Slab at the storage
63
4. Precast concrete staircase

 Length x height x width = 300mm x 165mm x 600mm
Figure 26 : view of staircase
Figure 27 : staircase at site
64
4.8.1 CONNECTION OF THE PRECAST CONCRETE
4.8.1.1 Column to column connection
The system used of jointing between the two columns component is by using direct end
bearing system. By which, dowel is locating on the upper part of the column as illustrated
in the drawing below. When a continuity of reinforcement is required, the reinforcement
from the upper and lower column is left exposed and either lapped or welded together.
Then, the completed joint is usually finished by casting concrete around the joint.
column
Figure 28 : Drawing of column to column Connection dowel
Link
Figure 29 : column under construction
65
4.8.1.2 Column to beam connection
The method used in jointing the column to beam is by using dowel connection where the
bars projecting from the column into steel tube cast into the beam. The tube is later being
filled with high strength of shrink grout.
Figure 30 : View of column to beam
beam
Figure 31 : Column to beam under construction
66
4.8.1.3 Column to base connection
The column and the base is joined by using dowels bars project from the footing with
matching cast in grout tubes in base of the column.
Figure 32 : Column to footing
column
base
Figure 33 : column to base under contruction
67
4.8.1.4 Column to slab connection
Before the slab is jointed, the slab must be supported by temporary support used to keep
the slabs in the position until the connection with the columns has been achieved.
In the connections, the steel bars (dowels) that project from the edges of the slabs are
welded to the dowels of the adjacent components and transverse reinforcement bars are
installed in place. The connections are then filled with concrete that is poured at the site.
Figure 34 : Slab column edge connection
slab
Figure 35 : Column to slab under construction 68

4.8.1.5 Slab to slab connection
Low strength of shrink grout is poured into the gap between the ends of the planks.
Figure 36 : Plank to plank connection
Slab to slab
Figure 37 : Slab to slab on site
69
4.8.2 The Manufacturing of Precast Concrete ( column)
steel
Reinforcement
cage
70
The
reinforcement
cage is inserted
into the mould
IBS mould
skip
concrete
71
vibrator
Harden concrete
72
Precast column
IBS mould
reinforcement
Precast column
73
4.8.3 Erection Procedure
Figure 38 : Erection Procedure Stage 1 to 3
74
Figure 39 : Erection Procedure Stages 4 to 6
75
Figure 40 : View the starter bar
Starter bar
Figure 41 : Show the starter bar
76
Prop for Put the column at

maintain the the right place
column
Figure 42 : View to put the column
Put the column at

the base
Figure 43 : Construct column on site
77
Beam to
column
Figure 44 : View of beam to column
beam to column
Figure 45 : Construct beam to column
78
Beam
Figure 46 : view of beam to column
Beam to column
Figure 47 : Construct beam to column
79
Figure 48 : View grouting the precast
Grouting
and vibrate
Figure 49 : Grouting on site
80
grouting
Figure 50 : View cast in situ
Cast in-situ
concrete topping
Figure 51 : Cast in situ concrete
81
4.8.4 INSTALLATION OF PRECAST CONCRETE COLUMN
The columns are lifted off from the delivery

vehicle and stacked properly in a place.
Lift and rig the columns to its lifting point

properly by using the crane and support
it with props.
After the first columns are fully tied to the

ground or slab, the next columns are
loaded for further vertical alignment.
82
The props should remain in position while

loading all the columns.
Concrete and grout all the columns.
The columns are already erected.
83
4.8.5 INSTALLATION OF PRECAST CONCRETE BEAM
Lift and rig the beams to its

position (on to the
framework/ column).
The lifting of the beam is by using the wire

ropes and should be properly handled by
crane.
The beam is fixed to its

supporting member.
84
Fills the space

around the
connection with
concrete and
grout as it will
fixed to the
column's heads.
Temporary
proping may be
used until the in-
situ grout
connection has
matured.
85
4.8.6 INSTALLATION OF PRECAST CONCRETE FLOOR SLAB
The hollow core slab is lifted by using a The sequences of fixing floor slab must
crane. be continuously in one direction.
Welded connection between the floor and

the beams.
The hollow cores should be closed off at a
Grout in between the precast slab to distance of not more than 100mm to one
provide shear key joint. another.
86
4.8.7 INSTALLATION OF PRECAST CONCRETE STAIRCASE
Set a level for

landing slab 1
and landing
slab 2.
Lift the
staircase to its
position by
using a crane.
The staircase is
placed to its
position and
concrete is pour
to connect the
staircase with
the landing.
87
The landing of
the staircase is
pour with
concrete.
The staircase
is already
installed.
The real
view
88
4.8.8 PLANTS AND MACHINERIES
A crane mounted on an
undercarriage with four rubber
tires that is used on site to pick
and carry the precast
component from one place to
another.
- It is a complete equipment to
produce the concrete, consists of
mixer, batching machine,
weighing system and control
system.
- It can produce the concrete
according the formula.
To transport the precast

component from the factory
to the site.
89
A temporary platform to give

access for doing the work and
to carry materials into a higher
place on site.
To transport the precast component from the

factory to the site.
90
4.9 PROBLEM DURING CONSTRUCTION OF PROJECT
They are a few of problem that may arise on site during the construction of the project and
there are:
1. Transporting
 Moving the component without proper tie-down may cause damage to the
precast component. The component will possibly break and cannot be used.
 The heavier of the precast component compared to wood or steel making the
transportation from the factory to the site more difficult. The large section of
the precast component also give difficulties while transportation.
2. Plant and machineries
 For example, the crane used for the lifting of component is lack of fuel.
3. Jointing
 Sometimes, the connection is not tightly jointed. Where the leakage can occur
at the loose part of the jointing.
 The component that need to be jointed does not matching into one another.
4. Drawing
 Sometimes the consultants changes or amend the drawing for their own
purpose.
5. Force major
 We as human being cannot control the environment such as weather, flood

and earthquakes.
6. Raw material’s quality
 For example, sand too moist or dry
91
4.9.1 Problem Solving
The problem occurs during the construction of project must be solve to ensure the project
can be done properly. So that, a few solutions to the problems are as follow:
1. The damages or broken to the precast component can be avoided by carry or

tie-down the component properly. The method of loading the component can be
done as illustrated in figure below:
Figure 52 : How to unload components edge lift and

single row
Figure 53 : How to unload components single row and

double row
92
Figure 54 : How to unload component 4 high and 2 high
Figure 55 : How to unload components 3 high equal

and 3 high double load
2. Other than that, to avoid damages to the component, the lifting insert and the
rigging for tilt up panel should be so arranged. So that, the lifting panel can
remains stable while lifting.
Figure 56 : How to stabilize the component
93
3. In order to make sure that the component is tightly jointed, the marking and
measuring work must be done carefully and thoroughly. Ensure that the
components are connected in a correct position.
4. Keep the updated drawing to prevent from wrong marking and always liaise with
the site coordinator.
5. When there is a sign to a bad weather such as raining, the work must be stop.
6. The problem on the quality of raw materials can be solve by control on physical
and chemical properties.
7. Engineer or department need to checking before and after the pour of concrete.
94
5 BUDGET AND EXPENSES FOR THE COURSE WORK
Table 2 : Budget for the course work
ITEM PRICE (RM)
Transportation to site 60.00
Telecommunication 10.00
Photocopy 3.00
Printing 70.00
CD 1.00
TOTAL 144.00
95
6 CONCLUSION
By doing this assignment, a lot of useful information and benefits are gain especially
regarding to our topic ‘Industrialised Building System’. Overalls, There are many types of IBS
existing in Malaysia which are formwork precast load bearing wall panel, precast frame, precast
floor and hollow core slab, sandwich panel, block panel, and steel frame. Quality, speed of
construction, and cost savings are the main advantages of these systems. These factors are very
important in implementing the Ninth Malaysia plan. The main disadvantages of the IBS in
Malaysia are that they are highly capital intensive and there is a need for experts at the
construction site for some of them. The main reason to recommend the use of IBS in Malaysia is
that the raw materials used in the IBS have to be produced locally in order to overcome the
shortages that are being faced by the IBS construction industry.
Other than that, this assignment also gives us many experiences such as experience in
communicate and interact with other parties, experience in construction site and many more. All
these experience is very beneficial to us.
Finally, we hope that this coursework can be guidance for us and also for other people in the
future. Also, the knowledge and experience gain can be implementing and practicing to the daily
life.
96
7 BIBLIOGRAPHY / REFERENCES
A. REFERENCES
1. IBS Definition –
http://www.ibscentre.com.my/ibsweb/index.php
2. Definition Of Industrialised Building System –
http://www.scribd.com/doc/49707474/Definition-Of-Industrialised-
Building-System
3. Albert G.H Dietz (1971) Industrialized Building Systems for Housing.
4. Abraham Warszawski (1999) Industrialised And Automated Building

Systems. A Managerial Approach. 2nd edition.
5. Industrialised Building System (IBS) Research and Information. Retrieved

October 10, 2011.
http://ibsresearch.blogspot.com/ .
6. Definition of Industrialised Building System (IBS). Retrieved September

25, 2011.
http://www.ibscentre.com.my/ibsweb/index.php
7. Benefit of using Industrialised Building System (IBS). Retrieved

September 25, 2011.
http://www.cidb.gov.my/v6/?q=en/faq/13
8. Principle of IBS. Retrieved November 13, 2011.
http://ibsresearch.blogspot.com/2010/04/article-for-building-investment-
b.html
9. Modular Coordination –
http://www.scribd.com/doc/51583552/Modular-Coordination-Ibs
97
10. Industrial Building System by JaspalAzam, Hidayah, Sharon, Syafiq, Ooi

2009 –
http://www.scribd.com/doc/21794505/Ibs-Complete
11. Industrial Building System –
http://ibsresearch.blogspot.com/
12. IBS Construction –
http://www.cidb.gov.my/v6/?q=en/content/150
13. IBS sustainability –
http://penerbit.uthm.edu.my/ejournal/images/stories/IJSCET1/IJSCET_1_
A10.pdf
B. BIBLIOGRAPHY
1. Nuzul Azam Haron, Ir. Salihuddin Hassim, Assoc. Prof. Ir. Dr. Mohd.
Razali Abdul Kadir and Mohd Saleh Jaafar (2005). Building Cost
Comparison Between Conventional and Formwork System. Jurnal
Teknologi, Universiti Teknologi Malaysia 43(B) 1-1
2. Nuzul Azam Haron, Ir. Salihuddin Hassim, Assoc. Prof. Ir. Dr. Mohd.
Razali Abdul Kadir. Building Cost Comparison between Conventional and
Composite Construction System In Malaysia. Universiti Putra Malaysia.
3. W.A.Thanoon, Lee Wah Peng, Mohd Razali Abdul Kadir, Mohd Saleh
Jaafar, Mohd Sapuan Salit. The Essential Characteristics Of
Industrialised Building System. Universiti Putra Malaysia.
98
8 APPENDIX
99

Title: Construction Technology Ii Course Work Report: Siti Nadiah Binti Mokhtar Noor Safika Faezan Binti Azahari

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TITLE:

SITI NADIAH BINTI MOKHTAR

NOOR SAFIKA FAEZAN BINTI AZAHARI

Subject: CONSTRUCTION TECHNOLOGY II (SBEQ1122)

CONSTRUCTION TECHNOLOGY 2 SBEQ 1122

We feel very grateful that we are able to complete this assignment in a

Our grateful thanks also go to Mr Ridhwan as the supervisor site at the

Great deals appreciated to the Perpustakaan Sultanah Zariah, UTM

2 INDUSTRIALISED BUILDING SYSTEMS (IBS) ...................................................................... 4

2.9.2 MOMENT RESISTING CONNECTION .................................................................... 38

4 CASE STUDY .............................................................................................................................. 54

Figure 1 : Type of Building System in Malaysia .............................................................................. 13

TABLE 1 : Building System Classification According to Relative Weight of Component.........20

1.1 INTRODUCTION OF THE STUDY

1.1.1 Statement of problem

1.2 BACKGROUND OF STUDY

2 INDUSTRIALISED BUILDING SYSTEMS (IBS)

According to official portal of CIDB Malaysia, Industrialized Building Systems (IBS) is

Warswaski (1999) expounded that an industrialization process is an investment in

2.2 HISTORY CHRONOLOGY OF HOUSING

Although incorporated in 1974 as a construction company, the SP Setia story really

Industrialized Building Systems (IBS) is defined as the complete assembly construction: a

Industrialised Building System (IBS) is defined as a construction technique in which

2. Planning is essential. IBS requires thorough arrangement of detail design, work

4. Obtaining manufacturing input at an early stage of the project is essential to IBS

12. There is no reason why construction approach to components production should be

Industrialising construction by way of manufacture of building components and delivery

2.4 WHAT IBS IS ALL ABOUT

Industrialized Building System (IBS) is a technique of construction whereby components

2.5 OBJECTIVE OF IBS

2) Formwork Systems – tunnel forms, EPS-based forms, beams and columns

4) Prefabricated Timber Framing Systems – timber frames, roof trusses, etc;

5) Block Work Systems – interlocking concrete masonry units (CMU), lightweight

2.1 CLASSIFICATION OF BUILDING SYSTEM

The classification of building system may be classified in a variety ways, depending on

Figure 1 : Type of Building System in Malaysia

2.1.1 CONVENTIONAL CONSTRUCTION METHOD

2.1.1.1 Casts-in-situ Construction Method

2.1.1.2 Composite Construction Method

2.1.1.3 Pre-fabricated Construction Method

2.2 CLASSIFATION OF IBS

2.2.1 CONVENTIONAL CONSTRUCTION METHOD

2.2.2 LINEAR SYSTEM OR FRAMES (BEAMS AND COLUMN)

 Columns, beams, frames, or trusses made of plain or prestressed concrete is used as

 Always used in the construction of bridges, parking lots, warehouses, industrial

2.2.3 PANEL SYSTEM

 May be prefabricated with a considerable amount of finish work.

 Reduce the content and amount of skilled labour onsite.

 It is economical use of room-size floor components.

 An aesthetic as their joints are not seen by the user.

Figure 2 : Frame System

Figure 3 : Panel System

2.2.4 RECTANGULAR OR BOXES SYSTEM OR TRHEE DIMENSIONAL

 The size is determined by transportation and erection considerations.

 It can contain more finish works than other prefabricated forms.

 A maximum saving of human labour onsite.

Figure 4 : Box System

2.3 CLASSIFICATION ACCORDING TO MATERIAL

2.3.2 BRICK AND BLOCK WORK

Steel construction essentially contains factors of prefabrication which is one of thecriteria

2.3.4 REINFORCED CONCRETE

2.4 CLASSIFICATION ACCORDING TO RELATIVE WEIGHT OF