INTRODUCTION Background The industrialised building system (IBS) can be generally interpreted as in which all buil di ng components ar e mass pr oduced ei ther in a factory or at si te fact or y according to specifications with standardise shapes and dimensions and transported to the construction projects site to be rearrange with certain standard to form a building. The devel op ment of industrialised buildi ng sy stem (I BS) is no t new in the construction industry. The history of precast in Uhousing dates from the mid !"##$s% whe n this and other forms of industrialised (prefabricated) construction w ere used to address the problem of widespread destruction of housing stoc& during the Second 'orld 'ar. In the United States% the use of precast in the construction industry began in the construction of prefabricated steel house by eneral ouse in !"*#. owever the ear ly eff orts of rationalisin g and implementation fad ed +ui c&l y due to pri ce in compet itiv eness% hig h cap ital and inc ons ist ent loc al cod es. The use of precas t increased sharply after the Second 'orld 'ar due to the need to resolve critical shortage of houses. In ,al aysia% the implementation of precast con cept by usi ng precast con cre te building were introduced in ,alaysia in !"-- when the government launched two pilot projects for precast housing which involves the construction of Tuan&u bdul /ahman 0lats in uala 1umpur and the /ifle /ange /oad 0lats in 2enang. Both projects were the first time whereby precast elements were used to construct mass houses. 1at er% 2erbadananemajua n3e ger i 4ohor (23S) import the precast con cre te tec hno logy fro m er many for the con str uct ion rangin g from low cost housing to lu5urious housing such as bungalows and semidetached. Today% many private companies in ,alaysia have teamed up with foreign e5perts from ustralia% 3etherlands% United States and 4apan to offer precast solutions to their projects. 3umerous construction projects have utili6ed the precast components especially to meet the re+uirement of time constraint and with high accuracy and
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The industrialised building system (IBS) can be generally interpreted as in which all
building components are mass produced either in a factory or at site factory
according to specifications with standardise shapes and dimensions and transported
to the construction projects site to be rearrange with certain standard to form a
building.
The development of industrialised building system (IBS) is not new in the
construction industry. The history of precast in U housing dates from the mid!"##$s% when this and other forms of industrialised (prefabricated) construction were
used to address the problem of widespread destruction of housing stoc& during the
Second 'orld 'ar.
In the United States% the use of precast in the construction industry began in the
construction of prefabricated steel house by eneral ouse in !"*#. owever the
early efforts of rationalising and implementation faded +uic&ly due to price in
competitiveness% high capital and inconsistent local codes. The use of precast
increased sharply after the Second 'orld 'ar due to the need to resolve critical
shortage of houses.
In ,alaysia% the implementation of precast concept by using precast concrete
building were introduced in ,alaysia in !"-- when the government launched two
pilot projects for precast housing which involves the construction of Tuan&u bdul
/ahman 0lats in uala 1umpur and the /ifle /ange /oad 0lats in 2enang. Both
projects were the first time whereby precast elements were used to construct mass
houses. 1ater% 2erbadananemajuan3egeri 4ohor (23S) import the precast
concrete technology from ermany for the construction ranging from low cost
housing to lu5urious housing such as bungalows and semidetached.
Today% many private companies in ,alaysia have teamed up with foreign e5perts
from ustralia% 3etherlands% United States and 4apan to offer precast solutions to
their projects. 3umerous construction projects have utili6ed the precast components
especially to meet the re+uirement of time constraint and with high accuracy and
The term =Industrialised Building System $$ is often misinterpreted as system limited
only for the buildings% whereas it is in fact cover all types of structures as the word
>building$ actually relates to >constructing$. It not only building% e5ample bridges%
highways% tunnels% dams.
Is a term used in ,alaysia for a techni+ue of construction where by components are
manufactured in a controlled environment% either at site ? off site% placed and
assembled into constructions wor&s.
8I9B@ 8onstruction process that utili6es techni+ues% products% components or
building systems that involved prefabricated components and on site installation.
Is the term to represent the prefabrication and construction industriali6ation concept
in ,alaysia. The term was joined to shift from the typical paradigm of prefabricated
system IBS has been introduced as a method with better productivity% +uality and
safety.
IBS can defined as products% systems and techni+ue used in ma&ing construction
less labourAoriented% use more machines% faster as well as +uality controlled. Itgenerally involves prefabricated products% factory manufactured elements that
transported to the construction sites and erected. (Shaari% <##)
Industrialised process is an investment in e+uipment% facilities% and technology with
the objectives of ma5imising production% minimisinglabour resources and improving
+uality while a building system is a set of interconnected element that joint together
to enable the designated performance of a building. ('arswas&i% !""")
ccording to 8I9B ,alaysia% IBS may be defined as >construction systems in which
component are manufactured% on or offAsite% positioned and assembled into a
structure with minimal additional site wor&s$.
7sa and 3uruddin (!""C) asserted that an IBS is a continuum beginning from
utilising craftsmen for every aspect of construction to a system that ma&e use of
manufacturing production in order to minimise resource wastage and enhance value
could be classified in different ways% depending on the particular interest of their
users or producers. Such classification use construction technology as a basis for
classifying different building systems. In this manner four major groups can be
distinguished namely% system with timber% steel% cast in situ concrete% and precast
concrete as their main structural and space enclosing materials. These systems can
be further classified according to the geometrical configuration of their main framing
components as follows linear or s&eleton (beams and columns) system% planar or
panel systems% and three dimensional or bo5 systems.
,aj6ub (!"DD) e5pounded that the relative weight of components should be used as
a basis for building classification is presented in Table !. The factor of weight has
significant impact on the transportability of the components and also has influence
on the production method of the components and their erection method on site. The
classification by weight also has the advantage of distinguishing between the various
basic materials used in the production of component which by itself could determine
the characteristic of the system under study. owever% ,aj6ub$s classificationmethod is found to be inade+uate to incorporate other building system flourish
recently. Ene of the distinct e5ample is the interloc&ing load bearing bloc&s which
was the brainchild of a group of researchers in Universiti 2utra ,alaysia. This new
building system cannot be categorised according to frame% panel or even bo5
system. En the other hand% the composite system that combines two or more
construction method cannot also be categorised under the ,aj6ub$s classification.
ence% the classification needs to be updated to reflect the current technological
0or accomplishing the re+uirement of modular coordination% all the components need
to be standardi6ed for production. Such standardi6ation of space and elements need
prescribing tolerance at different construction stages such as manufactured
tolerance% setting out tolerance and erection tolerance% so that the combined
tolerance obtained on statistical considerations is within the permitted limits (Tri&ha%
!"""). 2roduction resources can be used in the most efficient manner if the output is
standardi6ed. Then the particular process% machinery and wor&ers training can be
best absorbed to the particular characteristics of the product.
,ass 2roduction@The investment in e+uipment% human resources and facilities associated with
industriali6ation can be justified economically only when a large production volume isobserved. Such volume provides a distribution of fi5ed investment charge over a
large number of product units without unduly inflating their ultimate cost (8I9B
Singapore% !""<).
Speciali6ation@1arge production output and standardi6ation of preAcast elements allow a high
degree of labor speciali6ation with the production process. The process can be
subdivided into a large number of small homogeneous tas&s. In such condition%
wor&ers are e5posed to their wor& repetitiously with higher productivity level.
ood Ergani6ation@igh production volume% speciali6ation wor& and centrali6ation production re+uires
an efficient and e5periences organi6ation capable of high level panning% organi6ing%
coordination and control function with respect to production and distribution of the
products ('ars6aws&i%!""").
Integration% 2lanning and 8ontrol of the 2rocesses@In order to obtain an optimal result% a high degree of coordination must e5ist between
various relevant parties such as designer% manufacture% owner and contractor. This is
archived trough integrated system in which all these functions are performed under unified authority ('ars6aws&i% !"""). The design% manufacture% assembly and other
related process re+uires a coherent structure and management from the start to the
end in order to reach the goal and deliver a ma5imum value to the customers.
thorough planning of all activities is therefore re+uired especially in the early stage of
projects where e5tra attention must be paid to design (architectural as well as
engineering)% planning and preparation. By wellAprepared processes% complete
design when the production starts and the use of separately developed technical
system% supported by structured planning methods% the e5ecution of the process will
run smooth and with a low amount of defect and errors. The strive is towards 6ero
defects and minimum amount of waste (1essing et. al% !""").
2roduction 0acility@The initial capital investment for setting up a permanent factory is relatively
e5pensive. 2lant% e+uipment% s&illed wor&er% management resources need to be
ac+uired before production can be commenced. Such huge investment can only be
brea&even if there is sufficiently high demand for the products. En the other hand% a
temporary casting yard or factory can be established at the project site in order to
minimi6e the transportation costs (2eng% !"C-).
Transportation@It is found that casting a large panel system can reduce labour cost up to *# percent.
owever% these cost savings are partly offset by the transportation costs. The
transportation of large panels is also subject to the road department and relevant
authorities (2eng% !"C-).
7+uipment at site@
0or the purpose of erecting and assembling preAcast panel into their position% heavycrane is re+uired especially for multiAstory building. It is therefore important to
incorporate this additional cost when adopting a preAfabrication system ('ars6aws&i%
Industrialised Building System is a system which use industrial production
techni+ues either in the production of components or assembly of the building or
both. (0arid'ardi !""D). Under this system% the industry operate more li&e a
manufacturing sector where most parts of building is made up of manufactured
components and installed on site. The system can either be Epen or 8losed system.
8lose system (8S)@
closed system can be classified into two categories% namely production based on
client$s design and production based on precaster$s design. The first category is
designed to meet a spatial re+uirement of the client$s that is the spaces re+uired for
various functions in the building as well as the specific architectural design. In this
instance% the client$s needs are paramount and the precaster is always forced to
produce a specific component for a building. En the other hand% the production
based on precaster$s design includes designing and producing a uniform type of building or a group of building variants% which can be produced with a common
assortments of component. Such building includes school% par&ing garage% gas
station% low cost housing% etc. 3evertheless these types of building arrangement can
be justified economically only when the following circumstances are observed
('ars6aws&i% !""").
closed system can be classified into two category such as the production based on
the design form the owner or client and the production is based on the preAcaster$s
design. The first category is design to fulfill the space re+uired for any function in the
building as well as specific for the architectural design. In this case% he owner or
client re+uirement is the one important that company need to ta&e focus% and preA
caster$s is need to be forced to produce a specific component to type of building or a
group building variants% where it can be produced with a common assortment of
component. The building such as 2ar&ing garage% school% gas station% low cost
house and other.
But this type of building arrangement can only justified as economically when thefollowing are observe% such as the si6e of project is large enough to allow the
distribution of design and production cost over the e5tra cost per component incur
due to the specific design% the architectural design observe large repetitive element
and standarsation in respect to this% a novel prefabrication system can overcome the
re+uirement of many standarsation element by automating the design and
production process. There get enough demand for a typically type of building such
as school so that a mass production can be obtained. nd the last one is there is an
intensive mar&eting strategy by preAcaster to enlighten the client and designer the
potential benefit of the system in term of economic and noneconomic aspect.
0ollowing the approach classified in the si5ties as closed building system first a
project is designed and secondly subdivided into a number of building parts which is
will be produced especially for that project. In all case a lot of component are bought
on the mar&et% therefore one should ta&e care that certain dimension of the selfA
produced building part fit with these other component% li&e an e5ample% an apartment
bloc& is divided during the design process into concrete wall and floor plates. These
concrete element are designed in such a way that the connection s between them
are possible. t the same time one should ta&e care that the opening in the wall
element are coordinated with the window or doors one wants to use. lso thesanitary e+uipment should be fit.
Epen System (ES)@
In view of the limitations inherent in the closed system% an open system which allows
greater fle5ibility of design and ma5imum coordination between the designer and
precaster has been proposed. This system is plausible because it allow theprecaster 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 e5periences one major
setbac&. 0or e5ample% joint and connection problem occur when two elements from
different system are fi5ed together. This is because similar connection technology
must be observed in order to achieve greater structural performance.
The term =Epen Building SystemF is used when the starting point is totally different.
Ene does not start from specific project but one develops set element which is can
be combined in many way so the term can be used when two following condition are
fulfilled such a limited number element which are part of the system%% an unlimited
number of different project can be reali6ed. There will however always be a set of
constrain for the design of those project. The =design guideF will inform the designer
of the rules he has to follow (grid% positioningArules% re+uirement for stability) the
=element catalogueF provide an overview of all the possible element of a system and
the second is the building element of that EBS are coordinated with component of
different producer. This is the condition already necessary for a Semi open buildingsystem.
The main objective is to introduce the new concept system of Epen building system
(EBS) in <#!#% it$s the long term and systematic approach toward a positive
development of building industry. The EBS not only reengineer our construction
process such as supply chain% trade% design and other% but it transform the way of
doing the business in construction. Its allow opened supply of IBS where the
construction can bid the lower price with other company. Its stronger recommend to
allow the manufacture and assembler to enter the mar&et% thus its reducing the price
of IBS component. The EBS open the chance of new business and built the new
company that more small and medium for Bumiputera to able produce construction
components.
Epen building system also give a value to the customer or client with provide theaesthetical% the practical selection and fle5ibility for the construction product mar&et
since the supplier will only be motivated to invest in new product and innovation
solution if they can fore see enough sale. 1ocal technologies on IBS component
such as in lightweight components and interloc&ing bloc&s can be fully utili6ed. EBS
allows at some points% customers and house buyers to be involved in design% trough
selection of building components at the onset of the project. The adoption of the
EBS together with fully utili6ation of IBS will greatly benefit the building industry as itincreases the production capacity% lower manpower re+uirement% shorten
construction time% improve +uality and in the long run bring down the overall building
cost.
The following condition must be fulfilled li&e it must be possible develop different
EBS. 9ue to the general rules governing those system concerning dimensional coA
ordination% compatibility of performance) the decision to choose one specific EBS
can be postponed during the design process as long as necessary in a specificsituation. 1i&e an e5ample during the design process on has decided not to use a
bearing wall structure but a s&eleton. Ef course at the moment system ma&ing use a
bearing wall are e5clude but the competition is open between system based on
concrete or steel% between column and beam system and portal frame. The same
building parts and the Epen Building Sub system can be integrated in as many
different EBS as possible. The building part of different EBS can be e5change as
The concept =Epen Industriali6ationF is not only incorporating prefabrication% but also
rationali6ed traditional method li&e system for in situ shuttering% system for
rationali6ed bric&laying.
Industry through the government bodies such as 8I9B and SI/I, need to build or
develop with the standard ,alaysia for the component of IBS. It$s important because
two prefabricated part only fit on the building site if their dimension and the joint used
in closed system protected by patent. They are specifically design to fit the preA
caster prefabricated component and it is not supporting holistic concept of openness
in EBS. Through their research by 8I9B% construction research institute of ,alaysia
(8/7,) has been collaborated with 2ublic wor& department (2'9) and also from
the University of 3ottingham to see the strength% stiffness% ductility and stability of theconnection. EBS able to target the achievement for the mar&et because the
customer will li&e the aesthetical and the design space of EBS system.
,ar&eting EBS concept to this target group will give a huge and profitable mar&et
since the supplier will only be motivated to invest in new products and innovation
solution if they can foresee enough sales. 7ducate the customers to be more
involved in design stage is the way forward to promote EBS. 8ustomer can choose
their building materials at the onset of housing development. This can create good
mar&eting gimmic& to developers in order to attract homebuyers. 9evelopers% then
can play their role to advice designers to design according to ,odular 8oordination
(,8) and based on available IBS components in the mar&et. Then% the contractors
will pay the role of coordinating the installation of components according to
customer$s wish. Based on IBS /oadmap% 8I9B will publish EBS /oadmap%
introduce EBS Steering 8ommittee% to conduct EBS international seminar% publish
EBS catalogue and to use EBS as a main criteria to judge the contender for ,alaysian 8onstruction Industry 75cellent ward (,8I7).
IBS /oadmap also &een to produce more Bumiputera contractor to be as a
manufacture or erector in the near future. The construction of lifeAsi6e structures at
the compound of IBS 8entre% uala 1umpur will be the first ever attempt at showA
casing a diverse range of products and techni+ues in the construction technology
mar&et. The full scale structures will demonstrate attempts at using the EBS and
The 8lose system is follow to the rules of dimension% position and interface of
component are important elements of 8S. It can be defined as selfAcontained and
independent of system with the following characteristic@
!) 0actory fabrication?production and site assembled<) /e+uired sophisticated organi6ation*) /e+uired efficient transport system) 7ach system is uni+ue:) !##; factory made component (fabrication) and assembly at site.-) /e+uire sophisticated organi6ation. The si6e of project is large enough to
allow for distribution of design and production costs over the e5tra cost per
component incur due to the specific design.D) The architectural design observes large repetitive element and
standardisation. In respect to this% a novel prefabrication system can
overcome the re+uirement of many standardised elements by automating the
design and production process.C) 7ach system is uni+ue and cannot combine with other system.") There is an intensive mar&eting strategy by precaster to enlighten the clients
and designer the potential benefit of the system in term of economics and
noneconomic aspects.!#)/e+uire efficient transport system and sufficient demand for a typical type of
building so that a mass production can be obtained.
Epen building system
The open building system is follow to the rules of dimension% position and interface of
component are important elements of EBS. It can be defined with the following
characteristic@
!) Epen system building is the innovative design and construction<) The open system is fle5ibility component that can change and subsystem
from variety of manufacture and supplier.*) Its ta&e the advantage of an open mar&et of building component that fit
together% geometrically and functionally for a wide variety of building type.) Its will increase the encourage participation from manufacture and assembler
to enter the mar&et% and at the same time it will reducing the price of IBS
:) It strive the concept of modularity and separate the different of level of
decision ma&ing.-) The use of standard jointing system to fi5 two or more system together in one
building.
D) It able to discuss with the client to choose any component of building with use
the catalogue of component that already prepared or provide by the company.C)") Uniform with standards dimension and joint for building component. ,ethod
and coordination is not so different in each component.!#)EBS will encourage higher level of industrialisation through preAassembly and
automation!!) It allows interchangeability of components and subAsystem from variety of
manufactures and suppliers.!<)1arge scale demand and encouraged by government due to wide job
opportunity it can create.!*)Uniform standard component help to ease in building maintenance due to
easy obtaining building component from suppliers.!)8ooperation G coordination is importance between designer% manufacture G
building firm.!:)It allows customer involvement in design. 8ustomer can chose any building
components using components catalogue provided by the developers.!-)The fle5ibility to coordinating and interchanges building component must be
smooth.!D)0le5ibility to combine with costume precast design component G traditional
method.!C)It advocates a concept of modularity and separation of different levels of
decisionAma&ing.!")The use of standard jointing system to fi5 two or more system together in one
building.<#)It ta&es advantage of an open mar&et of building components that fit together%
geometrically and functionally for a wide variety of building types.<!)It will encourage participation from manufactures and assemblers to enter the
mar&et% thus reducing the price of IBS components.
Im&ortant To Im&lement Industrialised Building Sytem 'IBS( In )alaysia
*ecause+
!) igh demand from the clients in construction activities.
<) igh number of foreign labor to be employed to do the hand jobs. 'ith the
implementation of Industrialised Building System (IBS)% the number of
foreign labor and the cost of the construction project can be reduced.*) The economical forces can be one of the reasons why the Industrialised
Building System (IBS) is so important to our country. This factor may affect
the organi6ational of the clients and also the construction progress.) Benefits to adopters in term of cost and time certainty% attaining better
construction +uality and productivity% reducing ris& related to occupational
safety and health% alleviating issue on s&illed wor&ers and dependency on
manual foreign labor and achieving ultimate goal of reducing overall cost
of construction (8onstruction /esearch Institute of ,alaysia% <##").
ISO ,--- . /uality management
ISE "### is a +uality management standard that presents guidelines intended to
increase business efficiency and customer satisfaction. The goal of ISE "### is to
embed a +uality management system within an organi6ation% increasing productivity%
reducing unnecessary costs% and ensuring +uality of processes and products.
The ISE "### family addresses various aspects of +uality management and contains
some of ISE$s best &nown standards. The standards provide guidance and tools for
companies and organi6ations who want to ensure that their products and services
consistently meet customer$s re+uirements% and that +uality is consistently improved.
Standards in the ISE "### family include@
ISE "##!@<#!: A sets out the re+uirements of a +uality management system
ISE "###@<#!: A covers the basic concepts and language
ISE "##@<##" A focuses on how to ma&e a +uality management system more
efficient and effective
ISE !"#!!@<#!! A sets out guidance on internal and e5ternal audits of +uality
management systems.
ISO ,--0+1-02
ISE "##!@<#!: sets out the criteria for a +uality management system and is the onlystandard in the family that can be certified to (although this is not a re+uirement). It
Specific spheres of control in the built environment. The built environment can be
seen as having an hierarchical structure in which higher levels serve as the setting
and conte5t in which lower levels operate. s such% higher levels
e5ercise dominance over lower levels% while lower levels are dependant on higherA
level structures. 75amples of levels include urban design and architecture% or base
building and fitAout.
<. Base building@
The part of a multiAtenant building that directly serves and affects all occupants. In
conventional 3orth merican practice% base buildings are constructed by speculative
office building developers% leaving choice and responsibility for the reminder of the
buildingKthe fitAout A to occupants. The base building normally includes the buildingLs
primary structureM the building envelope (roof and facade) in whole or partM publiccirculation and fire egress(lobbies% corridors% elevators and public stairs)M and
primary mechanical and supply systems (electricity% heating and air
conditioning% telephone% water supply% drainage% gas% etc.) up to the point of contact
with individual occupant spaces. Base buildings provide serviced space for
occupancyM Supports is another term for base building.
*. 0itAout (tenant wor&)@
The physical products and spaces controlled by the individual inhabitant or occupant
used to ma&e habitable space in a base building. 0itAout can change without forcingthe base building to change.
. 8apacity@
The measurable +uality of a base building to accommodate a range of variations
in floor plan and use within the constraints of a given base building. ,ore generally%
capacity concerns the degree of Epen Building freedom offered by a higher level to a
lower level.
lobal movement@
!) 8I9B?overnment adopted this approach in IBS initiative<) lobally accepted features @
!. ,ultiA suppliers<. 0le5ible 1ayout (2ast K Eccupation)*. 2refabrication. 1ife K cycle:. Ewn fitAout?interior -. /aised ? fle5ible floor system
In Epen Building System (EBS)% a building can use two or more systems. It allows
openness to selects components supplier where everybody can bid to produce lower
price of components. ,anufacturer and installer will loo& for cooperation models that
will create benefit for both. EBS also allows the precaster to produce a limited
number of elements with preAdetermined range of product and at the same time
maintaining architectural aesthetic value. The cost of building components will be
reduced in the long run where plenty of options are available in the mar&et. It also
permits hybrid application.
The &ey aspect of EBS is dimensional coordination to allow fle5ibility in form of
construction% and the capacity to deal with differences in dimension and tolerance. In
order to obtain an optimal result% a high degree of coordination must e5ist betweenvarious relevant parties such as designer% manufacturer% owner% and contractor. This
is achieved through an integrated system in which all these functions are performed
under a unified authority. Therefore the subdivision of the building process needs to
reflect the lines of decision ma&ing and the definition of responsibilities between the
parties. This subdivision can then be translated into specifications for connections
between building parts.
Epen Building System (EBS) was first promoted during the rebuilding years of postA
war 3etherlands. The rules for dimensions% positions and interfaces of components
are important elements of EBS.
There are several advantages of open building system@
!) EBS is an innovative design and construction
<) It allows interchangeability of components and subAsystem from variety of
manufactures and suppliers*) It ta&es advantage of an open mar&et of building components that fit together%
geometrically and functionally for a wide variety of building types) It will encourage participation from manufactures and assemblers to enter the
mar&et% thus reducing the price of IBS components:) It advocates a concept of modularity and separation of different levels of
decisionAma&ing
-) The use of standard jointing system to fi5 two or more system together in one
D) It allows customer involvement in design. 8ustomer can chose any building
components using components catalogue provided by the developersC) EBS will encourage higher level of industrialisation through preAassembly and
automation
") 1onger life span!#)Speed of construction!!)3on dependence on uns&illed wor&ers!<)Technology intensive methods!*)igher level of productivity!)Significant changes to project management including the need for off site
management!:)Increased efficiency and speed!-)Improved +uality!D)Improved predictability
!C)In the longer run this system provide cheaper construction cost
Closed Building System
closed system can be divided into two categories% namely design and production
according to customer design and production based on preAcasters. The first
category is designed to meet customer space re+uirements% that is% the specific
building design and construction of various features of the space re+uired. In this
case% the customer needs is critical% preAcaster always forced to a specific part of the
building. En the other hand% the fabrication on the basis of preAcasters design%
including design and production of a single building type or alternative of a group of
buildings% can generate common component assortments of. Such building includes
school% par&ing garage% gas station% low cost housing% etc. 8ommitment because of
specific design and project large enough to allow for the additional cost of each
component in design and production costs of distribution.
Epenerved a large number of architectural design elements of repetition and
standardi6ation. In this regard% a new &ind of prefabricated systems can automated
the design and production process to overcome a number of standardi6ed elements
of the re+uirements. There is sufficient demand% is a typical types such as school
construction% so that mass production can be. There is a preAcaster intensive
mar&eting strategy to inspire customers and designers in the economic and nonA
economic aspects of longAterm potential benefits of the system.
There are several advantages of closed system@
!) ,eet customer re+uirement that increasing satisfaction and demands
<) 2rovide fle5ible design that could suitable with any type of building*) 4ust need specific space) Increasing cleanness at the site:) /educe construction period
-) /educing labour during prefabrication of component and site wor&sD) These method are easy to understand and constructC) 8onstruction component are guaranteed follow the standard") 2rovide perfect and fully function of construction component!#)There are no wastage and totally could reduce construction cost
T%$S O# IBS
%R$C"ST CONCR$T$ #R")IN56 %"N$! "ND BO7 SST$)S
I3T/E9U8TIE3
,ost common group of IBS products and use the permanent concrete formwor&s.
group of IBS which are cast under a controlled condition and moved to the job site.
TN27S E0 2/78STI3@
!) En site which is in the prefabrication yard.
<) EffAsite which is in the factory.
93T7S E0 2/78ST 8E38/7T7 U3ITS@
!) 8asting ta&es place in computerAcontrolled facilities where an e5perienced
crew produces units under close supervision.
<) 0orms are on the ground% ma&ing the placing of steel reinforcing% casting and
The construction industry plays a big role in ,alaysia$s development and e5pected
be a major contributor towards the realisation of ,alaysia ision <#<#. lthough the
construction industry is very competitive% it is currently very labourAintensive. The
ineffectiveness and low productivity are caused by the failure of the industry to utili6ethe new as well as other relevant labourAreducing technologies.
IndustrialisedBuilding System (IBS) is a building systems in which structural
components are manufactured in a factory% on or off site% transported and assembled
into a structure with minimal additional site wor&s. In order to remain competitive
especially in the era of globali6ation% the ,alaysian government has formulated a
roadmap called IBS roadmap <##*A<#!# to promote the usage of IBS in the local
construction industry. Ene of the targets is to reduce the level of foreign wor&ers to
only !:; by the year <#!#.
Besides reduced dependency on labour% the simplified construction solutions also
offer better control of +uality% increased productivity and faster completion% less
wastage% neater and safer construction sites and cleaner environmentM which lead to
a lower total construction costs. The usage of IBS is not new in the ,alaysian
construction industry% particularly the usage of precast concrete elements in the
construction of dwelling units since nearly four decades ago. 0rom there% numerousconstruction projects in ,alaysia have utili6ed IBS% especially when there
re+uirement is to build fast and with high precision and +uality. 3evertheless% the
usage of IBS in the ,alaysian construction industry is still very low if compared to
the conventional method. recently completed survey conducted by
8onstruction Industry 9evelopment Board ,alaysia (8I9B) on the application of IBS
by ,alaysian contractor$s shows that the usage in local construction projects is
Industrialised Building System (IBS) is regarded as many terminologies such as a
product% process% techni+ue% approach% system and development model. There have
been many programmes and promotions by ,alaysian overnment in order to
implement the IndustrialisedBuilding System (IBS) as an efficient and valuable
construction system. 7ven though the IBS has been used since !"--% there is not an
agreed definition on Industrialised Building System (IBS) which could elaborate this
construction method. 3evertheless% there have been a number of studies which
describe the Industrialised Building System (IBS) as offAsite method (manufacturing%
production and construction)% construction and building system (automation% nonA
traditional Industrialisation% innovative solutions% modularisation% prefabricated%
precast and preAassembled.
8onse+uently% without considerations to these various definition the main objective of
IBS construction implementation is to improve the efficiency% +uality% cost
effectiveness% safety and health% waste reduction and effectiveness within the
construction industry. To achieve this objective% IBS should be viewed as altering the
conventional perception% improving the capability and competency% enhancing the
cooperation% trust and team wor&ing% encouraging the innovation and attaining the
high integration. 8onse+uently% major advantages of Industrialised Building System(IBS) implementation are@ faster and cleaner construction% less labour% wastages and
construction costs% site materials reduction% better +uality and effective site
management% improve standardi6ation and +uality improvement that ultimately will
produceimproved IBS within the construction industry.
IBS is not new in ,alaysia and have beenaround since the early si5ties. The first
pilot project was initiated by the overnment and itwas along 4alan2e&eliling which
involved*%### units of low cost flats and # shop lots.owever% developments in IBS
after that failedto gain support from the industry andconsumers. 0rom a survey done
by 8I9B on<##*% it was found that the percentage usage ofIBS in the local
construction industry is only ata mere !:;. owever% several major worldclass
developers in ,alaysia have used some percentage of IBS in their projects.
mong the reasons that have made IBS notvery popular with the developers would
betheabundance of cheap foreign labours in thecountry. 8urrently there are about
<:#%###wor&ers in the construction industry. Theovernment effort to reduce the
7ven so% the usage of IBS in building isstill low. 0rom a survey conducted by8I9B,alaysia% the usage level of IBS in the localconstruction industry stands at only
!:; (IBSSurvey <##*). The early efforts of theovernment to encourage the use of
IBS in theconstruction sector has yet to garner a good response% and this sector is
still practicing conventional construction methods that
have proven time and again to be wasteful%dangerous and messy. /elatively% the
lowlabour cost in this country is the root cause ofthe industry failing to reform and
beingcomplacent with the current level
of productivity% +uality and safety. owever% itcannot be disputed that to be
competitive at theinternational level% it is important for the,alaysia construction
industry to evolve and beready for the globali6ation era where anincrease in
The industry needs one fundamental planthat involves all the important aspects in
thisevolution process. In this respect% the IBS/oadmap <##*A<#!# is formulated as
areference for all parties in implementing
all programmes towards the modernisation of the,alaysian construction sector. The
IBS/oadmap <##*A<#!# has been discussed anagreed upon at the national level
through theIBS Steering 8ommittee and 'or&ing roupsorgani6ed by 8I9B
,alaysia where themembers are represented by the governmentsector% developers%
manufacturers% contractors% professional bodies% higher learning
institutions%associations% and other interested parties in theconstruction industry. The
IBS Steering8ommittee and 'or&ing roups have producedthe IBS /oadmap <##*
A <#!# based on the :A, strategy (,anpower% ,aterialsA8omponentsA,achines%
,anagementA 2rocessesA,ethods%,onetary and ,ar&eting) and will also ensurethat
its programs are implemented to meet thetotal industriali6ation of,alaysia$s
construction industry by the year <#!#.
En achieving a wider scale implementationof IBS scale for ,alaysia% the
overnment willalso give full e5emption on levy imposed By 8I9B for developers
who utili6e IBScomponents e5ceeding :# percent. These wisedecisions made by the
overnment willdefinitely create a lot of interest from theindustry to use IBS as analternative approachof construction. The ne5t stage of IBS would beto e5plore the
(e5port) of the system to overseasmar&et. The success of these efforts will enablethe
local construction industry to becompetitive and penetrate the global mar&et.
luminium 0ormwor& System is a construction system for forming cast in place
concrete structure of a building. It is also a system for scheduling and controlling the
wor& of other construction trades such as steel reinforcement% concrete placement
and mechanical and electrical conduits. The System is fast% simple% adaptable and
very cost effective. It is uni+ue because it forms all of the concrete in a building
including walls% floor slabs% columns% beams% stairs% window hoods% balconies and
various decorative features in e5act accordance with the architectsL design. The
dimensional accuracy of the concreted wor& also results in consistent fittings of
doors and windows. The smoothKoff form finish of the concrete eliminates the need
for costly plastering. luminium 0ormwor& System provides luminium 0ormwor& for /88 load bearing or /88 framed multiAstoried buildings and enables the walls and
slabs to be poured in the same operation. These increases efficiency and also
produces an e5traordinarily strong structure with e5cellent concrete finish. 9ue to the
fine tolerance achieved in the machined metal formwor& components% consistent
concrete shapes and finishes are obtained floor after floor. This allows plumbing and
electrical fittings to be prefabricated with the certain &nowledge that there will be an
e5act fit when assembled. Unli&e other construction systems% 0ormwor& Systems of aluminium forms can be erected by uns&illed lab our and without the need for
hoisting cranes. The largest panel weighs not more than <: which means it can
0iberglass /einforced 2anels (0/2) are plastic sheets that come in both flat and
corrugated options. They have a wide variety of uses including roofing% s&ylights%
wall covers% greenhouses% and more. 0lat plastic panels commonly have designs%
te5tures% or patterns molded into the plastic% while corrugated plastic sheets are
typically smooth to the touch. 0/2 are more dimensionally stable than competing
materials such as 28 or polycarbonate. They can be used over a much broader
temperature range without concerns of warping% e5cessive e5pansion and
contraction or crac&ing and brittleness that is commonly associated with competing
materials. 8orrugated plastic sheets are available in various strengths and colors
depending upon application and budget. These range anywhere from economicalagricultural grade panels to e5tra strong% woven roving reinforced industrial grade
panels where strength and impact resistance are important. 0iberglass roofing
panels are also suitable for use in highly corrosive environments where e5posure to
chemicals or saltwater is a concern% are U resistant to sun e5posure and can be
made with fire retardants when re+uired. eavyAduty commercial grade fiberglass
sheets that are available in either flat or corrugated. The fiberglass panels are
partition wall is a wall that separates rooms% or divides a room. 2artition walls are
usually not loadAbearing. 2artition walls are constructed of many materials% including
steel panels% bric&s% bloc&s of clay% terraAcotta% concrete% or glass bloc&s. enerally
these are nonAload bearing walls and therefore% their cross section is ta&en thin.
2urpose of 2artition walls are to divide the floor area of the building and for privacy
purposes for the inhabitants of the building.
dvantages of 2artition walls is that these walls can be easily constructed because
they are thin in cross section. These walls are light in weight as their cross section is
thin so they occupy less area of the floor.
The Di::erence *et;een %artition and Bearing Walls<
There are two types of walls in a house% partition and bearing. 2artition walls dividethe interior space into rooms but support no weight. Bearing walls function as
dividers% but they also hold up part of the house.
Serving as important structural elements% bearing walls transfer the weight of the roof
and upper floors to the foundation. ll e5terior walls are bearing walls. They support
the roof at the ends of the joists. The interior bearing walls support the floors above
and the attic weight. They support the joists at midpoint.
2artition walls construction in concrete% plain or reinforced may be cast in situ or built
from panels or bloc&s% precast wall in advance of the commencement of wor&.
enerally for cast in situ walls% !# cm thic& and below% the reinforcement consistingof mild steel bars or B / 8 fabric is placed in the centre of the wall thic&ness.
8oncrete mi5 usually adopted in the wor& is ,!: (!@<@). The wall is cast
monolithically with the intermediate columns so as to be rigid and stable both along
its length and height. In case of precast concrete partition walls% precast concrete
slab panels and special shaped concrete post are used. The slabs are generally *<
mm thic& and are inserted in the grooves of the precast post and the joints are
,etal lath and plaster when properly laid forms a reinforced wall which is thin%
strong% durable and is considerably fire resistant. The metal lath is available in
variety of patterns and it generally re+uires a framewor& of steel or timber for the
purpose of fi5ing it in position. In case of partition walls with steel frames% lath is
generally tied by galvani6ed iron wire to mild steel bars or channels spaced !: to *#
cm apart. The latter is fi5ed on one side and the plaster is applied on both sides of
the lath. This type of partition wall may be : to D.- cm in thic&ness.
In order to achieve improved insulation against heat and sound% metal lath and
plaster partition walls can also be made with a cavity between the wall thic&ness.
This type of hollow partition wall is constructed by fi5ing the metal lath on both sides
of specially shaped steel channels spaced at *# to : cm apart. 9epending upon the
width of cavity desired% the channels are generally * to !#cm deep.
< "<C< Sheet or 5<I< Sheet &artitions+
2artition walls constructed from asbestos cement sheeting or galvani6ed sheet fi5ed
to wooden or steel members are mostly adopted in wor&s of temporary character.
These walls are economical% light and fairly rigid if constructed properly.
0or superior type of asbestos cement sheet partition walls% specially manufactured
slabs of the above said material are used. 7ach slab consists of core or corrugated
asbestos cement sheet with the plain asbestos cement sheet attached to it on either
side. The use of such slabs renders the partition wall more fireAresistant and ma&es it
have good heat and sound insulation properties.
@< Tim*er &artitions+
This type of partition walls consists of a wooden framewor& either supported on the
floor below or by side walls. The framewor& consists of a rigid arrangement of timber
members which may be plastered or covered with boarding etc from both the sides.
Such partitions are not fireAresistant and the timber forming the partition is li&ely to
decay or be eaten away by white ants. 'ith the introduction of new building
materials% the use of timber partitions is getting gradually reduced these days.
Bene:it o: constructing dry &artition ;all<
dvanced dry partition wall has emerged as the new focus to modern technology inhomes. The major developers have led the industry into using dry partition walls
between rooms in their residential projects. The constant improvement in
performance for plasterboard to suit the use in residential projects has ensured that
such wall system now meets high level specific cations in the areas of acoustic
insulation% thermal insulation and resistance to fi re and damp conditions. Besides
meeting statutory functional re+uirements such as fi re ratings% the heavy dutydrywalls are able to resist high impact and support loads such as televisions and
cabinets. 2erformanceAwise% the system is suitable for severe duty usage% having
passed the strength and robustness tests such as@ Stiffness% 9oor Slam% and Impact%
eavyweight nchorages tests% in accordance to Singapore Standard SS"<@<##!.
igh performance drywalls are tested to severe duty standards in strength and able
to withhold minimum loading of <: &g at each point. The fi re rating for the board is
about ! hour which satisfy as the fi re safety re+uirement for residential buildings.
9espite the =heavy dutyF label% the drywalls are lightweight (about !#A!:; the weight
of conventional bric& walls)M allowing designers to adopt lighter structures% which
results in savings in foundations cost. The drywall system is slimmer than
conventional bric& walls% thus creating more usable space for the rooms.
Installation o: dry &artition ;all<
The ease of installation of mechanical and electrical (,G7) services within the
boards will reduce the noise pollution that may be created with the hac&ing of bric&
walls to embed the services% providing a cleaner and environmentally friendly site.
The drywall system can be easily installed and +uic&ly relocated according to one$s
needs. omeowners can renovate and redesign the interior layouts within a shorttime% there is no messy hac&ing of concrete or bric&s and no debris to the
0or light and medium duty anchor for fi 5tures such as mirrors% light fi tting or picture
frames on drywalls% simply use screwdriver to insert and tighten the screw until
secure. There is no need for hammer drills to ma&e holes in concrete or bric& and no
unsightly chun&s of concrete or bric& brea&ing out through imprecise wor&manship.
The drywall system is also able to support heavy fi 5ture such as large wallcupboards and heavy wall cabinets% but homeowners are advised to get contractors
to carry out the installation wor& with proper heavy duty anchors. 9evelopers li&e