W7 IBS in Malaysia A Way Forward

IBS in Malaysia, A way
forward.
Sr Ts. Muhamad Zaihafiz bin Zainal Abidin
The best preparation for tomorrow is doing your best today.

Content
• Introduction – historical views, concept
• System of IBS component
• Current updates on IBS
• Types of IBS Jointing
• Calculating IBS Score
• Management issue on IBS
• Case study on MZH building IBS

Intro
• Malaysia
• 1964: Research by KPKT in europe
• 1966: Pilot project – Flat Pekeliling
i. 7 blok 17 tingkat, -
ii. 3000 unit kos rendah
iii. 40 kedai
• JV Gammon (Kontraktor) Flat Pekeliling KL
• (system) Larsen dan Nielsenpanel timber formwork precast concrete
enmark; complete within 27 month

• 1969: 6 blok 17 tingkat dan 3 blok 18 tingkat di
Jalan Rifle Range, Pulau Pinang.
• Build by Hochtief and Chee Seng; system Estoit
from France
- Taman Tun Sardon,

Pulau Pinang (1,000 unit
blok lima tingkat); sistem
BRECAST dari UK
Rifle Range Penang

4
IBS keep on expand
• Housing project around 1970-1980an
• Hybrid approach starts around 1990an
i. KLIA,
ii. Stadium Bukit Jalil,
iii. Putrajaya,
iv. KL Sentral, Menara KL,
v. KLCC,
vi. LRT dll.

Adopted from Fateh, 2020

Manufacturing process

Current status on IBS
• Maintaining momentum for Government projects worth RM10
million and above using IBS need to archive minimum IBS
score of 70%
• Increase the use of IBS in private projects with minimum IBS
scores of 50%

Why do we need IBS?
• Higher reduction of site labour
• Low wastages
• Less site material
• Cleaner environment
• Better quality
• Safer construction sites
• Fast completion and
• Lower construction cost

Closed system
Always third
First a project Then a system
party supply
etc.
mass - production
one end product

Open system
Then many
First a system Open supply
projects
DESIGN GUIDE
?
CATALOGUE
etc.

System of IBS
Blockwork
In situ concrete Steel frame
system
Timber frame Reusable formwork

Hybrid, etc

Example of IBS project

Daya bumi

Approach of IBS

Cash flow for Physical progress for
IBS project conventional project
Cash flow for

conventional
Physical progress for

IBS

Modularisation

Glance of Modular concept in IBS
Conversion from metric to 3M

Metric Modular coordination

Conversion from metric to 3M

Jointing and connection
of IBS

Structural Systems
• The structural systems of precast concrete can be categorised into
two(2):-
a) Panel Unit b) Framing Unit
The best preparation for tomorrow is doing your best

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25
Introduction – Panel Unit
• The structural framework of the building is composed of precast concrete slabs and load-bearing
walls.
• The slab and wall components are manufactured in factories or fabrication yards on site and then
transported to building site.
• Consequently, the number of wet trades involved on-site can be reduced significantly.
• With careful design, thoughtful planning and good coordination between designers and erectors.;
the erection process can be very fast.
• Panel unit can be applied on:-

✓ This system is preferred for the construction of uncomplicated buildings like hotels, hostels and
government apartments such as teachers’ quarters.
✓ These buildings normally offer less degree of flexibility in which major modifications, such removal of
load-bearing walls, are restricted during their service life.

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Structural System – Panel Unit
• The system is simple and basically comprises of
precast/cast in-situ slabs supported by load-bearing
walls.
• The span between the load-bearing walls creates a

free open space. For internal layout, light wall
partitions are used.
• The stability of the wall buildings depend on the wall

and slab panels.
• The precast concrete slabs must be ensured to act as a

stiff diaphragm and capable of transmitting lateral
forces to the shear walls.
• In the precast wall system, the two essential

connections to be considered are the vertical and
horizontal connections.
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Introduction – Framing Unit
• The framed buildings consist of beam, columns and slabs

components that are fabricated or “manufactured” off-site
using machines and formworks.
• This building system offers quality materials, fast-track

erection, robustness, durability and stability.
• The system is normally chosen for any type of building

because of its common requirements, such as:
✓ Requirement with respect to comfort such as spacious area.
✓ Flexibility for future modifications.
✓ Ample floor-to floor clearance height.
• This system is suitable for buildings that need a high degree of

flexibility in terms of larger clear distances between columns
such as office buildings, school buildings, hospitals, university
buildings, commercial buildings and car parks

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Structural System – Framing Unit
Non-structural or load-bearing walls can also be incorporated in the frame.
For car parks, office buildings and shopping complexes, the most common floor layout is such that precast
beams are arranged in the longitudinal and transverse directions of the building respectively.
Flat or wide rectangular precast concrete beams are generally more commonly chosen to support long-span
hollow core slabs.
The reason for this is that wide beams can provide enough bearing length for the slabs.

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Jointing Systems
Vertical load
• Structural connections are required to join all the structural

components of the beams and columns.
• The most important connections are beam-to-column,

column-to column and column to base connections.
• Structurally, the connections between components can be

pinned or rigid connections.
• Consequently, the complete concrete frames must be Lateral

designed to satisfy the performance required in terms of load
strength, stiffness, ductility, integrity and robustness.

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Aspects to be considered:-
1) Type of Structure 2) Frames Stability

To stabilize the frame, a suitable connection method
need to be applied and as such, it is advisable to:-
• Use a rigid connection between column and
beam
Wall System Frame System • Use a rigid or pinned connection between
column and base.
Unbraced Frames Braced Frames

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Rigid beam-to-column
connection
Unstable frame
Pinned base
Rigid base

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Frame can be stabilized using bracing systems such as shear wall, lift
shaft etc.
Pinned
connections
Rigid core
Unstable frame

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beam
Design in simply supported

or continuous beam
Can be use in half cast

Starter
1 Bars
2 3
Centre Point of
Foundation
Mark alignment of column Lifting of precast

and the center point of concrete column using Leveling shim
foundation for each crane plate
column.
4 Dowel Tubes Checking the verticality

of the column
Projecting starter /dowel

bars are inserted into the
dowel
tubes provided in the P.C. 5
Column

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6 Props 7
Holes provided -
for pouring of non
shrink grout
Propping of column using push
pull props Mixing of non shrink grout
8 9
Grouting the sides of the Non shrink grout is

base of the column poured by gravity into
the column
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Beam to Column
Two category:
a) Hidden connection
▪ Billet beam to column
▪ Welded plate beam to column
▪ Cleat beam to column
▪ Sliding plate beam to column
▪ Half beam joint
b) Visible connection
▪ Shallow corbel beam to column
▪ Deep corbel beam to column
▪ Nib beam to column (or wall)

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Hidden Connection
Cleat beam to column
Hole for the insertion of steel blade
Sliding plate beam to column

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Visible Connection
Dowel Bar
Bearing
Pad
Deep corbel beam to column
Corbel
Nib beam to column (or wall) The best preparation for tomorrow is doing your best today.
Page 43
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Column to Column
Beam to Beam

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Panel System
Precast Concrete Components in precast concrete wall building

Connections for Panel
Systems Precast concrete
slab
• Horizontal & Vertical Connection
1. Dry connection
2. Wet connection Horizontal
connection
• Connections play important role

in maintaining overall stability of Precast concrete
the wall building. wall
Vertical connection

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Horizontal Connection Vertical Connection
Vertical wet
connection
Dry connections: Utilize mechanical anchor such as

bolt & nut or welded steel plate to transfer load.

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Installation Process
• Precast Framing System

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Installation of column

Types of jointing in IBS
Precast concrete
Divide into
• Single tier
• Double tier
• Triple tier

slab
• Good quality.
• Normally used are hollow core
slab
• Can be used permanent
formwork
• Not required a lot of scaffold
• Not required a lot of formwork
• Fast erection and delivery

Types of IBS slab
• Hollowcore Slab
• Precast RC / Prestressed Plank
• Precast Half Slab
• Precast Single / Double Tee Slab
• Bubble Deck Slab
• Precast Toilet Slab

Wall to slab

Connection with corbel

IBS SCORE

Calculating IBS Score
• Part 1 – structural system (Max 50 points)
• Eg precast concrete
• Part 2 – wall systems (max 20 points)
• Eg dry wall, precast concrete panel, block work etc..
• Part 3 – other simplified construction solution (30 points max )
• Repetitive structural layout

• INFRA – 0 SCORE
• BUILDINGS – 100 SCORE
• Substructure – 0 Score
• Structure – 50 Score
• Walls – 20 Score
• Others – 30 Score

• STRUCTURE
• Components
• Columns
• Slabs
• Roof
• Systems
• Precast Concrete
• Formworks • Blockworks • Steel • Timber • Others

Understand wall in ibs score system
• Walls
• Brick
• Blocks
• Cast Insitu
• Precast Concrete
• Prefabricated
• Others

MODULAR COORDINATION
• Measurements
• Modul
• Conversion from metric / si into M
• Repetition
• Vertical/Horizontal Layout
• Sizes Of Components
• Doors • Windows • Structural Components

Higher IBS score is reflection of :-
• higher reduction of site labour
• Low wastages
• Less site material
• Cleaner environment
• Better quality
• Safer construction sites
• Fast completion and
• Lower construction cost

Typical method
statement of IBS

PENYEDIAAN PAPAK BAWAH
STEP 1: GROUND FLOOR
PREPARATION
• Preparation of foundation
• Casting of In-situ column stumps /
ground beams with protruding
starter bars ready to receive Precast
Columns
• Before start precast column
Protruding installation, installer will mark
Starter Bars control line for precast column

PEMASANGAN TIANG KONKRIT PRATUANG
STEP 2: COLUMN INSTALLATION
◼ Installer will install require no of
shim to make sure bottom of
column level is correct

INSTALLATION OF
PRECAST COLUMN
◼ Precast column is slotted into
Protruding
Starter Bars
protruding starterbar
Precast
Column

INSTALLATION OF
PRECAST COLUMN
◼ Column is propped to the
required level and verticality
Propping
Of Columns

INSTALLATION OF
PRECAST COLUMN
Grouting
Of Starter ◼ Column is propped to the
Bars
required level and verticality
◼ Column is grouted with high
strength non-shrink grout

INSTALLATION OF
PRECAST BEAM
STEP 3: BEAM INSTALLATION
• Precast beam is lifted into position
• Type of connection:
1) Hanger connection
2) Corbel connection

INSTALLATION OF
PRECAST BEAM
STEP 3: BEAM INSTALLATION
◼ Precast beam is lifted into position
◼ Corbel connection
- grouted corrugated sleeve
Precast
Beam

INSTALLATION OF
PRECAST SLAB
STEP 4: HOLLOW CORE SLAB
INSTALLATION
◼ Precast Hollow Core Slab is lifted onto
position by using clamper or lifting belt
Precast
Column Precast
Hollow Core
Slab
Precast
Beam

OTHER RELATED WORK
STEP 5: ASSOCIATED WORKS

◼ Shear key joint is grouted

OTHER RELATED WORK
Beam top
concrete STEP 5: ASSOCIATED WORKS
casting ◼ Shear key joint is grouted
◼ Installation of beam top rebar
◼ Beam top concrete casting

OTHER RELATED WORK
STEP 5: ASSOCIATED WORKS
◼ Shear key joint is grouted
◼ Installation of beam top rebar
◼ Beam top concrete casting
◼ M&E services installation
M&E
services
laying

Flexibility of Precast System
◼ Fixing of M&E Services onto Precast
Elements
Fixing of M&E Services

onto Precast Hollow
Core Slab

◼ Matching with Cast In-situ Members/
Steel Structure
Matching of Precast
Beam to Cast In-Situ
Beam

OTHER RELATED WORK
STEP 5: ASSOCIATED WORKS (Cont..)
◼ Placing of hollow core slab topping
reinforcement/wire mesh.
◼ Casting of topping concrete
Topping
concrete
Topping
rebar/mesh

HOLLOW CORE SLAB OPENING
Hollow Core Slab
l /b
150-165 200-215 265 325-500 • Openings on Hollow Core Slab
1 Center
-round
hole
-square
opening Ø 87 Ø 100 Ø 125 Ø 135
(maximum 87x1000 87x1000 87x1000 87x1000
3 voids in
the same
cross
section)
2 Front 500x0.2l 450x0.2l 550x0.2l 410x0.2l
3 Corner 390x0.2l 370x0.2l 400x0.2l 500x0.2l
4 Edges 225 180 200 245

VISIT MZH CONTENT

IBS facts in Malaysia
• Government is promoting.
• Most government building are required to achieve 70% IBS
score.
• To improve building quality, speed and cheaper.
• To reduce dependency on unskilled workers.
• Not that popular among private building projects except high
rise apartments.
• Cheap workers are still available for conventional methods.

IBS Problem In Malaysia
• Still regarded suitable for simple buildings like carpark, school, simple office
block and mass housing.
• Wrong perceptions given by consultants to client and developers due to
limited knowledge.
• Unpleasant past experience due to leakages, poor quality, abandoned project,
unattractive arch, etc.
• Many people involved in building industry do not have in-depth knowledge.
• Lack of interesting building erected using IBS.
• Monopolized by few contractors.
• Wrong approach (convert conventional to IBS).
• IBS manufacture not innovative to assist issues with designers.
• Only few IBS companies having full range of complete products.

Architect’s Problems in Producing
Outstanding IBS Design in Malaysia.
• Limited choice of building system and incomplete product.
• Limited choice of building material.
• Not many engineers willing to explore new technology
together.
• Most client are conservative.
• Clients do not give chance local architects.

MZH2 Experience – Contractor
Many jobs in hand due to Busy-not able to focus on Not enough trained
few players. the job. supervisor.
Still using foreign Still delay due Still many mistake during
workers. coordination/production. installation.
Transportation Workmanship still a Sub contract product

breakdown. problem. from other manufacture

Cased study The MZH building
• Build by Arkitek Suria
• Fully funded by consist college group
• Floor – floor level : 3m
• Land area : 1 acre
• GFA: 150,000 Sqft
• 16 million construction cost
• 14 month of construction of duration
• IBS 2
• 8 storeys
• 3 car park
• 14 classroom
• Hostel with 156 of student capacity
• Examination hall (100)
• Surau (100)
• Grand hall (1500)

A new paradigm of IBS. MZ perspective
• Just to promote IBS is not very challenging.
• To proof IBS2 can create interesting architecture.
• To relate IBS2 to energy saving architecture with lower operational
cost.
• To proof IBS2 is cheaper and faster to build.
• To proof IBS2 can produce good quality building.
• To be a showcase for IBS2.
• To blend IBS with other objectives to produce better outcome and
image.
• To create IBS2 as lifestyle solutions to building owners.

Industrialize building System
+ Innovative Building Solutions =
IBS2

Before choosing the system
• Check site constrain.
• Check compaction test on suitability of construction system.
• Ok, explore potential design possibilities.
• Provide basic drawings to tilt up contractor and choose.
• Select and further discussion.
• Get quotation.

Orientation study
- Sun
- Ventilation
- Rainwater harvesting
- Cantilever design
- Level of 3 m

The MZH building construction

Features in MZH 2
Natural ventilation on car parks

Lightweight block wall Lattice in bathroom
bare concrete finishes

Construction details from supplier
• Precast Column : 340 nos
Precast Beam: 356 nos
Precast Hollow Core : 6400m²
Precast Planks : 32m

Bare concrete finishes hollow core
Void for M& E
Stack effect in atrium

Continue

Advantages of IBS
Better Reduction of
Less volume of building
quality unskilled Less wastage.
material.
control. workers.
Increased
Safer and more environmental
Reduces completion and
organized construction
time of construction. construction
site.
site cleanliness.
Features of MZH2
80 % of components
of the building used Recycle steel for roof
IBS material with structure Rain water harvesting
bare concrete finishes
hollow blocks (at the Precast concrete (in UAC board and grass
staircase), car park level), pavers.
re wall, interlocking pavers, lightweight concrete

New trends in IBS

Conclusion
• IBS must not be associated only for mass housing and simple
construction.
• IBS must be exploited and further develop from time to time to suit
present trend and not just as profit making factory.
• IBS must be seen user friendly in order to encourage popularity.
• More interesting design buildings must be seen using IBS to attract
client and industry players.
• Student need to aware about the changes of game play in
construction industry.
• Well equipped students able to provide a competitive edge


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IBS in Malaysia, A way

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

- Taman Tun Sardon,

Rifle Range Penang

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

Timber frame Reusable formwork

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

Cash flow for

Physical progress for

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best today.

The best preparation for tomorrow is doing your best

• Panel unit can be applied on:-

The best preparation for tomorrow is doing your best

• The span between the load-bearing walls creates a

• The stability of the wall buildings depend on the wall

• The precast concrete slabs must be ensured to act as a

• In the precast wall system, the two essential

• The framed buildings consist of beam, columns and slabs

• This building system offers quality materials, fast-track

• The system is normally chosen for any type of building

• This system is suitable for buildings that need a high degree of

The best preparation for tomorrow is doing your best

Non-structural or load-bearing walls can also be incorporated in the frame.

The best preparation for tomorrow is doing your best

• Structural connections are required to join all the structural

• The most important connections are beam-to-column,

• Structurally, the connections between components can be

• Consequently, the complete concrete frames must be Lateral

The best preparation for tomorrow is doing your best

1) Type of Structure 2) Frames Stability

Unbraced Frames Braced Frames

The best preparation for tomorrow is doing your best

The best preparation for tomorrow is doing your best

The best preparation for tomorrow is doing your best

Design in simply supported

The best preparation for tomorrow is doing your best today.

Mark alignment of column Lifting of precast

4 Dowel Tubes Checking the verticality

Projecting starter /dowel

The best preparation for tomorrow is doing your best

Grouting the sides of the Non shrink grout is