Design Req.

For Contractor’s Proposed

IBS Building_Apr13

DESIGN REQUIREMENT FOR CONTRACTOR’S

PROPOSED IBS BUILDING

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IBS Building_Apr13

ITEM CONTENTS PAGE

1.0 Preamble 4
2.0 General 4
3.0 Contractor’s Professional Engineer
3.1 Introduction 4
3.2 Contractor’s PE 4
3.3 Scope of the Contractor’s PE’s Work 5
4.0 Design Requirements
4.1 Design Data 5
4.2 Design Standards 6
4.3 Design Consideration 7
4.4 Design for waterproofing 9
4.5 Design Documentations 10
5.0 Preparation Of Drawing And Detailing
5.1 Scheme Drawings 11
5.2 Construction drawings 12
5.3 Propping and shoring drawings 12
5.4 Endorsement of drawings 12
6.0 Submission of Documents and Drawings
6.1 Prior to commencement of work 13
6.2 During construction work 13
6.3 At the completion of the construction work 13
7.0 Design Verification and certification
8.0 Workmanship of precast concrete components 14
9.0 Installation
9.1 General 15
9.2 Transportation 15
9.3 Site acess and ground preparation 15
9.4 Placement of precast concrete components 16
9.5 Erection 16
9.6 Alignment 16

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9.7 Safety precautions during installation 16

9.8 Certification of completed installation works 17

10.0 STORAGE 17

ATTACHMENT :
Lampiran I : Standardised sizes for beam, column and slab

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1. PREAMBLE

This specification applies when the Contractor is required to submit

Contractor’s Proposed Design using Industrialised Building System (IBS) for
concrete building structure.

2. GENERAL

This specification outlines the requirements for the analysis, design,

detailing, drawing, manufacture, handing and erection of precast and precast
prestressed concrete building components including other related items such
as joints, connections, bearings and anchorages to ensure that all items act
together as an integral structure that is structurally stable under all specified
combination of loading conditions.

The Contractor shall employ a Registered IBS System Provider (RISP) as

approved by the Government to design all the required structural elements of
the buildings, regardless of whether the elements are precast or cast in-situ
concrete structures. The Contractor shall also employ the RISP to
manufacture and supply prefabricated or precast concrete part of the
required structural elements (thereafter called precast concrete
components), as specified.

The Contractor shall also with prior consent of the S.O employ Contractor’s
Professional Engineer (also referred to as Contractor’s PE) for the purposes
of endorsing the design and supervising the construction and completion of
the Works which relates to the Contractor’s Proposed Design.

All precast concrete components proposed to be used in the works shall be

approved by the S.O prior to installation.

3. CONTRACTOR’S PROFESSIONAL ENGINEER

3.1. Introduction

The Contractor shall take full responsibility for the integrity, thoroughness
and competence of the Contractor’s PE’s report and recommendation that
the relevant work (endorsement and supervision) has been adequately
carried out in accordance with accepted engineering practice, ensuring the
realization of structural integrity and stability of the proposed construction at
site.

3.2. Contractor’s PE

The names and professional qualifications of at least one individual

Professional Engineer who are competent in the field or disciplines of

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structural engineering shall be submitted by the Contractor for S.O’s

approval.

The proposed Contractor’s PE shall have at least 5 years of design work

experience at the professional level in the respective area of work.

The proposed Contractor’s PE shall not have any financial or professional

interest in the design proposal that he is endorsing and supervising.

3.3. Scope of the Contractor’s PE’s work

The Contractor’s PE shall be required to independently carry out review and

verification activities on the Contractor’s Proposed Design prior to the
endorsement. These activities shall include among other things;
a. Determining appropriate use of relevant Code of Practice and Design
Standards in the design work
b. Checking the design loading and method of construction
c. Checking the standards and specifications of materials to be used
d. Ascertaining the structural design concept used and identify the key
structural elements
e. Analysing all key structural elements of the building and the associated
structure to be built
f. Determining the stability of the structural frame
g. Checking structural detailing; and
h. Determining the adequacy of other aspects of the design which are
peculiar to the building and the associated structures to be built and
which are essential to the structural integrity of the works.
i. Reviewing and verifying the drawings produced and at the end of the
process certify that they have been drawn correctly, all in accordance to
the requirement of the design.

The Contractor’s PE shall also be required to supervise the construction and

completion of the Works which relates to the Contractor’s Proposed Design
in accordance to the Quality Management System as approved by the S.O.

4. DESIGN REQUIREMENTS

4.1. Design data

Unless specified otherwise, the value of loads selected for design shall
reflect the expected live loads to be exerted on the floor area as well as the
dead load from all other building components including the respective
precast and cast in-situ concrete components.

However, at no time shall these values be less than the recommended

values as stipulated in the following loading standards;

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4.1.1. Dead load

Dead load shall be specified as per requirement in BS 6399: Part 1 or BS EN

1991-1-1: 2002. However, it shall not be less than the requirements
stipulated in the Malaysian Uniform Building By-Law.

4.1.2. Imposed load

Imposed load shall be specified as per requirement in BS 6399: Part 1 or BS

EN 1991-1-1: 2002. However, it shall be not less than the requirements
stipulated in the Malaysian Uniform Building By-Law

4.1.3. Wind load

Wind load shall be specified as per MS 1553: 2002 or BS 6399: Part 2 or BS

EN 1991-1-4: 2005 with minimum basic wind speed of 35 m/s.

All design shall incorporate wind loading of 35 m/s or notional

horizontal load as specified in BS 8110 which ever than greater.

4.1.4. Loads associated with building services

Loads associated with the installation of building services, such as the

electrical lighting, air conditioning ducting, water tanks, fire fighting pipes,
water supply pipes and others shall also be ascertained and incorporated in
the analysis and design of the relevant supporting structures by the
Contractor.

4.2. Design standards

In general, all precast and cast in-situ concrete structures shall be designed
in accordance to the British Standard BS8110 Part 1: 1997 Structural Use of
Concrete or the equivalent Malaysian Standard or any other equivalent
internationally recognised standards.

All concrete works involved in the manufacturing of the precast concrete

components shall be carried out in accordance with the specification given in
Section D JKR Standard Specification for Building Works 2005.

All prestressing materials shall be either in the form of wires or strands and
are produced in accordance to the British Standard BS 5896: 1980
Specification for High Tensile Steel Wire and Strand for the Prestressing of
Concrete, or the equivalent Malaysian Standard or any other equivalent
internationally recognised standards. If prestressing strands are used in the
works, they all shall be of the low relaxation type.

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Minimum concrete cover to the steel reinforcement or prestressing wires,

tendons, cable or sheaths in any structural building components shall be as
specified and in compliance with the fire resistance requirements mentioned
in the Uniform Building By-Laws.

The minimum cover to reinforcement shall be 40 mm for columns and ground

beams and 25 mm for beams, walls, slabs and staircase

Design of large prefabricated panels shall be in accordance to the Malaysian

Standard MS1313: 1993 Code of Practice on Large Prefabricated Panels.

Building and component dimensions shall be standardised based on the

Modular Coordination concepts as stipulated in the Malaysian Standard
MS1064: 2001 Guide to Modular Coordination in Buildings.

4.3. Design consideration

4.3.1. General approach

All designs shall comply with the requirements of Industrialised Building

System. The minimum IBS content for structural system must not be less
than 40 points and achieved total IBS Score 70 points based on the
Construction Industry Standard, CIS 18:2010 published by CIDB Malaysia

All structural design shall comply with architectural design requirements as

stated in the architectural tender drawings.

The Contractor shall provide the design for the structural system of the
building only, e.g. columns, floor slabs and beams.

Optimum economic benefits are achieved by maximising the repetition of the

precast concrete components. As such, standardised sizes of these
components as given in Lampiran I shall be used whenever possible.

Precast concrete structures shall be designed as discrete components and

the continuity of the components shall be achieved through proper
connection details.

Weight of the components shall be appropriately restricted to comply with the

production, transportation and erection considerations.

Effects of restraint to the changes in volume cause by creep, shrinkage and

temperature differences must be considered in every structure.

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Beam-and-column connections used in the structures shall be of the types

without corbels. However connections using hidden corbel shall be allowed.

The contractor shall ensure that all M&E works are well coordinated with the
structural components.

4.3.2. Design principles

The structural framing of the building shall be designed as braced structures.

In order to do this, appropriate bracing elements such as shear walls,
staircase enclosures, lift cores, triangulated bracing or buttressing designed
to resist all lateral forces in the relevant planes shall be provided at the
required locations.

Whatever system of resisting horizontal forces is used, reversal of load

direction shall be accommodated. The floors shall have adequate strength
and be so secured to the structural framework as to transmit all horizontal
forces to the points at which such resistance is provided.

Precast concrete components that are designed as prestressed elements,

the flexural tensile stresses in the concrete should not exceed the Class 2
requirements, as stipulated in Clause 4.3.4.3 of British Standard BS8110
Part 1: 1997.

In the design of the lifting points, when lifting inserts are used, the inserts
shall be designed with minimum factor of safety of 4 at ULS against tensile,
shear and bonding failures. If reusable lifting hardware or rigging are used,
then they shall be designed with minimum factor of safety of 5.

The joint between the stump and the pad footing shall assumed to be pinned
to allow for uniform development of earth pressure under the footing.

All structural welding, if required shall be done by qualified welders using

equipments and materials compatible to the base material. The work shall be
done completely in the factory and no structural welding work shall be
allowed on site.

If proprietary joint system is specified, the capacity of the system shall be

justified either by calculation or by test results.

Non-load bearing blockwork shall be properly designed to ensure the safe

functioning of the walls. Proper attention shall be given to the stability of the
wall and appropriate vertical/horizontal wall stiffeners shall be provided for
every 10m2 area of wall or a minimum spacing of 3 meters. Lintols, ties,
reinforcements and connections shall be used judiciously.

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Unless specified otherwise, the minimum grade of concrete used to

manufacture the precast concrete components shall be 35 N/mm2 with
minimum cement content of 350 kg/m3 and the maximum free water cement
ratio is 0.5

Cast insitu infill grout shall be of grade at least 35 N/mm 2 or equal to the
grade for precast component.

When precast concrete wall panels are used as cladding, the inherent load
carrying capacity of these components may not be neglected.

4.3.3 Provision of chases, holes and openings on the structural element

The contractor shall coordinate the design of building and medical services
early to allow for appropriate design provisions be taken into consideration
during the design stage of the structural elements.

The contractor shall designed the structural element of the building in such a
way to enable the forming of all chases, holes and openings required for the
installation of building and medical services to be done during the
manufacturing of such structural element at the factory. The contractor shall
not be allowed to hack or break any building element after casting at the
factory or installation at the site without written consent of the S.O

4.4. Design for waterproofing

4.4.1. Internal joints

In the normally dry area (e.g. living rooms, bed rooms and stores) approved
bituminous based water proofing membrane shall be applied on top of the
joint between the slab panels. The end of the membrane shall be at least
200mm away from the end of the precast concrete floor panel in the joint.

In the normally wet area, (e.g. bathrooms, toilets and kitchens), approved
liquid water proofing membrane shall be applied over the entire floor area
with extra 200mm minimum up the walls and vertical pipes. Water proofing
admixtures are also introduced in the concrete screeds that are subsequently
laid on top of the concrete floor topping, if the screeds are specified.
Additives are also added to the concrete placed in the joints to improve
workability and reduce shrinkage.

In both areas (dry or wet), cast in-situ concrete topping of minimum grade 35
N/mm2 shall be laid on top of the waterproofing materials.

However, when the concrete topping is designed as structural topping to act

as a composite with precast concrete floor panel, the minimum thickness of

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the structural concrete topping shall be as per designed or 60mm, whichever

is greater. Screeds shall also be specified to be laid on top of the finished
composite floor panel and water proofing membrane, in addition to the
structural topping.

In other cases, the minimum concrete topping thickness shall be 30mm only.

4.4.2. External joints

Both the horizontal and vertical joints should be designed as ‘open-drained’

joints, meaning any water in the joint can flow down and discharged out on
its own by gravity.

On the vertical joints, a double barrier consisting of an internal barrier of

approved bituminous membrane and an external barrier consisting of
approved elastomeric joint such as polyurethane material lay between two
panels against a backup string of foam material.
Horizontal joint between external walls is waterproofed by means of
approved expendable self adhesive polyurethane foam strip. In addition, a
strip of approved bituminous felt is also laid horizontally at the intersection of
vertical and horizontal joints.

Both, vertical and horizontal joints shall then be concealed by installing

aluminium strips on top of the grooves and attaching one end of the strip to
the wall.

4.4.3. Leakage tests

In the normally wet areas (e.g. bathrooms, toilets and kitchens), 24-hour
water ponding tests shall be carried out. In this test, the area to be tested
shall be inundated with 50mm deep standing water for a continuous 24 hour
period. After the 24-hour period is over, a thorough inspection is carried out
to detect any sign of water leakage in and around the test area. The test is
deemed successful when no sign of any leakage is detected.

4.5. Design documentations

All analysis, calculations and design works carried out for permanent (e.g
beams, columns etc) and temporary (e.g propping, shoring etc) structures
shall be carried out in such a manner to allow ease of checking and
verification. Load combinations shall be clearly itemised and identified to
enable design checking to be carried out upon the most adverse conditions.
The works above shall be documented and compiled in a Design Document.

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The Design Document shall be certified and duly signed by the designer of
the structural elements of the building who shall be a current registered
Professional Engineer with the Board of Engineer, Malaysia.

In addition, the Contractor through his Contractor’s PE shall also

independently review, verify and certify the appropriateness of the design
work as recorded in the Design Document. The review work of the
Contractor’s Professional Engineer on the Design Document shall also be
properly documented. These documents shall then be consolidated in a
Design Review Report. The Contractor’s PE shall certify that the design work
has been done in accordance to the relevant acceptable standards prior to
the submission to the S.O for approval.

The designer of the structural elements of the building and the Contractor’s
PE shall formalise their endorsements by putting their signatures and
professional seals onto the pages of the consolidated Design Review Report
respectively.

5. PREPARATION OF DRAWING AND DETAILING

5.1. Scheme drawings

Scheme drawings shall consist of key plans of relevant floors including roofs,
cross-sections of buildings, cross-sections of building components, joints
details and bracing locations.

The drawings shall indicate the locations, sizes and arrangements of vertical,
sloping and horizontal concrete building components, such as floor slabs,
roof slabs, staircases and beams of both, precast and cast in-situ
components.

In addition, the scheme drawings shall also indicate in the plans and
elevations of the building, proposed arrangements of vertical, sloping and
horizontal precast concrete components, such as the precast concrete
columns, precast concrete staircases, precast concrete beams and precast
wall panels.

The column-to-column joints, column-to-beam joints, column-to-floor joints,

beam-to-beam joints, beam-to-floor joints, floor-to-floor joints including the
cut-outs on the precast floor slabs and any other required joints shall be
clearly shown. The details of corbels, well hidden to conform to architectural
requirements, or other mechanised connectors, if required shall also be
clearly shown.

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5.2. Construction drawings

Construction drawings shall consist of all fully completed drawings required

to enable the building to be constructed at site.

The drawings shall be detailed in such a manner to allow all necessary

information regarding the fabrication, transportation and installation of the
precast concrete components and construction of cast in-situ components to
be available for construction. This information includes the grade of concrete
used, actual dimensions of the precast and cast in-situ components, sizes
and locations of the steel reinforcements, sizes and location of the
prestressing wires or strands, concrete covers to steel reinforcements and
prestressing wires or strands. Details of the conduits for electrical and
mechanical services shall also be shown, when required.

In addition to above, construction drawings shall also show the sectional

properties of the components such as the cross-sectional area, moment of
inertia, modulus of section, distance to neutral axis together with the
designed bending and shear capacities.

The magnitude of all loads used in the design of the precast concrete
components shall be clearly stated in the drawings. The Contractor shall also
state clearly in the drawings the designed fire rating of each proposed
structural building component.

To ensure proper handling of the precast concrete components, all lifting and
erection devices shall also be clearly shown in the construction drawings.

5.3. Propping and shoring drawings

All structural precast components shall be properly stabilised during erection

stages by employing suitable temporary propping, bracing and/or shoring
systems. The Contractor shall propose such a system and produced design
calculations and drawings to allow for safe employment of the system on
site.

5.4. Endorsement of drawings

All drawings (scheme, construction and, propping and shoring) shall be

certified and duly signed by both, the designer of the precast concrete
components and the Contractor’s PE who are registered Professional
Engineer with the Board of Engineer, Malaysia.
The designer of the structural elements for building and the Contractor’s PE
shall formalise their endorsements by putting their signatures and
professional seals onto the pages of the submitted drawings.

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In addition, a certificate shall be issued by the Contractor’s PE with respect

to the drawings produced which relates to the Contractor’s Proposed Design
and any other associated structures such as temporary works stating that, to
best of his knowledge and belief, the drawings so checked do not show any
inadequacy in the relevant key elements.

6. SUBMISSION OF DOCUMENTS AND DRAWINGS

6.1. Prior to commencement of work

The Contractor shall submit the Design Document, the Design Review
Report, Method Statements, Quality Management System and delivery
schedules, duly certified and endorsed by the respective designer of the
structural element of the building and the Contractor’s PE to the S.O.

The Contractor shall also submit all required drawings duly certified and
endorsed by the respective designer of the structural element of the building
and the Contractor’s PE to the S.O.

6.2. During construction work

The Contractor shall submit monthly or as required by the S.O Supervision

Report pertaining to the construction progress of the Contractor’s Proposed
Design to the S.O. The report shall also incorporate documentations
generated as a result of the implementation of the approved Quality
Management System on site. The Supervision Report shall be duly certified
and endorsed by the Contractor, designer of the structural element of the
building and the Contractor’s Professional Engineer.

6.3. At the completion of the construction work

The Contractor shall submit a certification from the Contractor’s Professional

Engineer that the work which relates to the Contractor’s Proposed Design
has been completed and constructed in accordance to the approved design
drawings, specification and method statements.

7. DESIGN VERIFICATION AND CERTIFICATION

All analysis, design, drawings and method statement documents shall be

certified and duly signed by the designer of the structural elements of the
building, who is a registered Professional Engineer with Board of Engineers,
Malaysia and employed by the RISP, to the effect that the submitted
documents are produced in accordance to the accepted engineering
standards. The designer of the structural elements for the building shall
formalise his endorsements by putting his signature and professional seal
onto the pages of the submitted documents.

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In addition, the Contractor shall also appoint a Contractor’s Professional

Engineer who is also a registered Professional Engineer with the Board of
Engineers, Malaysia to independently check, review and endorse the
analysis, design, drawings and method statements produced by the designer
of the structural elements of the buildings on the Contractor’s behalf.

The Contractor’s Professional Engineer shall specifically describe any

deficiencies, potential or real, which have been identified along with the
relevant references to the accepted standards, practices and design
principles. The deficiencies should be illustrated wherever possible by
marking-up the drawings or with sketches, and such related materials. The
report may include the Professional Engineer’s suggestion, amendments,
alternative solutions and designs for the same. A tabulated summary of all
the Professional Engineer’s comments shall be included.

At the end of the design review and verification process, the Contractor shall
submit the Contractor’s Professional Engineer endorsement and certification
of the design in a consolidated document called certified Design Review
Report to the S.O prior to the commencement of work.

8. WORKMANSHIP OF PRECAST CONCRETE COMPONENTS

The concrete shall be dense and hard and substantially free from chipped
edges, laitance and honey combs. It shall also be free from fractures and
cracks and from any other defects arising from faulty materials used or from
faulty methods of manufacturing.

The surface of the precast concrete components shall not be coated with
cement wash or any other preparations that may hide the actual condition of
the concrete surface. No repairs shall be permitted on the precast concrete
components under any circumstances.

All materials, processes of manufacturing and finished precast concrete

components shall be liable to inspection and approval of the S.O. Such
inspection may be performed at the point of manufacture or delivery.

All precast concrete components shall be clearly marked with the

manufacturer’s name or registered trademark or logo, reference number and
casting date.

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9. INSTALLATION

9.1. General

The Contractor shall inform the S.O at least one week in advance of each
launching or installation operation and submit the following documents to the
S.O for acceptance:
a. Method statement including launching systems and transportation
b. Proposal for traffic diversion, if appropriate
c. Detailed programme of each launching or installation operation

9.2. Transportation

The Contractor shall obtain the necessary clearances for the transportation
of the precast elements and movement of the lifting equipment to the
launching site. Contractor’s method of transportation shall demonstrate that
the elements being transported would not be damaged.

Temporary support for precast concrete components during transportation

shall be designed to withstand loads and extra forces during loading,
transportation and unloading.

Precast concrete components shall be lifted and supported during

manufacturing, stockpiling, transporting and erection operations only at lifting
or supporting points, as shown in the fabrication shop drawings, and with
approved lifting devices.

The Contractor shall ensure that the precast concrete components are
loaded in sequence compatible with the required unloading and erection
sequence on site.

A certificate of test of lifting equipment shall be submitted to the S.O,

together with particulars of the experiences of the operator.

9.3. Site access and ground preparation

The Contractor shall be responsible for providing suitable access to the

building, proper drainage and firm, level bearing for the hauling and erection
equipments to operate under their own power.

The ground of the launching area shall be prepared at Contractor’s own cost
to ensure that it is safe to carry the required load during installation or
launching operation. To support the assertion that the launching area is safe,
calculations certified by Professional Engineer shall be submitted to the S.O
for approval.

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9.4. Placement of precast concrete components

The Contractor shall be responsible for providing true level surfaces on all
site placed bearing walls and other site placed supporting members.

The Contractor shall also be responsible of placement and accurate

alignment of anchor bolts, plates or dowel in column footings, grade beams
and other site placed supporting members.

All relevant shoring or propping equipments shall also be provided by the

Contractor, if composite beams or slabs are specified.

9.5. Erection

Installation of precast or precast prestressed concrete components shall be

performed by the manufacturer or a competent installer. Precast components
shall be lifted by means of suitable lifting devices at points provided by the
manufacturer. Temporary shoring, propping or bracing, if necessary shall
comply with manufacturer’s recommendations.

The removal of the temporary props, bracing or shoring devices shall only be
done after certification by the Contractor’s Professional Engineer that the
installation is stable and safe and approved by the S.O.

9.6. Alignment

Precast components shall be properly aligned and levelled as required by the

approved fabrication shop drawings. Variations between adjacent
components shall be reasonably levelled out by jacking, loading or any other
feasible methods as recommended by the manufacturer and approved by the
S.O.

9.7. Safety precautions during installation

Utmost precautions shall be taken to eliminate any danger to the workers

and general public while launching precast elements. All lifting equipment
shall be designed, such that if the primary lifting mechanism fails, a
secondary mechanism shall ensure that the precast element shall not fall.

Upon erection, a fail-safe method shall be used to temporarily secure the

precast unit until the permanent fixing arrangements shall be implemented.

The securing systems, subject to the S.O’s acceptance shall include:

a. providing chains between the installed precast concrete components and
stable supports

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b. connecting adjacent precast concrete components with temporary

bracings between them
c. providing wedges or brackets to the precast concrete components.

The Contractor shall inform the S.O and obtain his approval before removing
any temporary work but such approval does not relieved the Contractor of his
responsibilities for the safety of the work.

9.8. Certification of completed installation works

Upon completion of the installation works, the Contractor’s Professional

Engineer shall certify that the installation has been done in conformance to
the best engineering practices, all in accordance to the approved
construction drawings.

10. STORAGE

Precast concrete components shall be stored on only two point of support

located near those used for handling or lifting. Where points other than those
used for handling or lifting are used for storage, the storage condition shall
be checked and verified.

If the support is provided at more than two points and the design is based on
more than two supports, precautions must be taken so that the component
shall not bridge over one of the support due to differential support settlement.
Particular care shall be taken for prestressed components, with consideration
made for the effect of prestressing.

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