1

OBJECTIVES
At the end of this topic students should be able to:

1) understand the concept, benefits, types and
installation of IBS

2) make a comparison between the IBS construction
method with the other construction method


2
CONTENT
Definition
Why IBS
IBS in Malaysia
Characteristics of IBS
Benefits of IBS
Types of IBS
Problems in Using IBS
Modular coordination
Challenges in IBS



3
1. 100,000 units of affordable
homes to be implemented
through IBS

2. Commencing 2005, all
goverment project will use 50%
IBS components.

3. Housing projects which utilised
IBS components exceeding
50% will be given full
exemption on CIDB levy.

1. Efforts to encourage the use of Industrialised Building System
(IBS) will be continued in order to achieve the objective of
reducing dependency on unskilled labour as well as foreign
workers

2. The Government will ensure that the IBS components meet the
Malaysia Standard MS 1064. The adoption of the Standard will
ensure quality and will also control construction costs.

3. Capital expenditure on moulds to manufacture IBS components
be given accelerated capital allowance to be claimed for 3 years.
BUDGET SPEECH 2006
The Philosophy
IBS concept
The key idea behind IBS is to move as much of the
construction process from the construction site into
the factory environment - Offsite construction
Example: Typical 2-sorey building
Conventional method: Involve assembly of 1200 individual parts and thousands
of interfaces and joints higher chances for chaos
IBS method: Production of building components/modules at factory reduces on-
site assembly to only ~ 50 components or modules
What is IBS?
DEFINITION: IBS is a building system in which structural
components are manufactured in a factory, on or off site,
transported and assembled into a structure or building with a
minimal additional site works

A set of interrelated elements that act together to enable the
designated performance of a building
8
What is IBS?
IBS is a construction process that utilizes techniques, products,
components or building systems which involves prefabricated
components and on-site installation

The usage of IBS in Malaysian building industry is expanding,
catching up with civil engineering construction i.e. bridges, drains,
infrastructure projects
9
Completed Bldg.
CONVENTIONAL CONSTRUCTION METHOD
Construction Materials
Concrete
Bricks
Reinforcement
Timber
ON SITE
Completed Bldg.
IBS METHOD
Construction Materials
Concrete
Bricks
Block
Timber
Components @ module
pre-cast @ pre-fabricated
Wall Panel
Timber
Frame
Pre-cast
Staircase
Timber
Truss
ON SITE
OFF SITE
12
Why IBS???
IBS promises:
Better control of the process resulting in better quality and faster
production resulting in higher productivity and lower cost.
The cleaner and better working conditions of the factory will result
in safer and happier workers
Specialization would result in greater mechanization resulting in
lower labor requirements, better quality control and less wastage
Why IBS???
IBS promises:
Environmental impact of the construction process on the site is
also lower as a result.
The other spin off effect is that the factory workers have better
housing and more stable working conditions. Factories if properly
run will result in more stable job orders.
IBS in Malaysia
Poor Site Condition

The Current Scenario of Malaysian
Construction Industry
Messy sites
Poor S & H
High wastage
Labour intensive
Low quality
Delays
Almost
3 out of 4
workers deal in
wet trades


Ref: CIDB, 2003
Wet Trades Workers
The Current Scenario of
Malaysian Construction Industry
B
r
i c
k
l a
y
i n
g
,

3
1
1
4
C
a
r
p
e
n
t
a
r
y

,

2
9
4
0
C
o
n
c
r
e
t
i n
g
,

2
5
0
8
P
l a
s
t
e
r
i n
g

(
1
)
,

2
0
2
6
B
a
r
b
e
n
d
i n
g
,

1
5
6
2
P
a
i n
t
i n
g
,

1
1
3
5
P
l u
m
b
i n
g
,

6
1
0
B
u
i l d
i n
g

W
i r
i n
g
,

5
0
4
S
M
A
W

(
1
G
)
W
e
l d
i n
g
,

3
0
4
D
r
y
w
a
l l
I
n
s
t
a
l l a
t
i o
n
,

2
8
7
R
o
l l e
r

O
p
e
r
a
t
i o
n
,

2
1
1
P
l u
m
b
i n
g

,

1
4
7
T
i l i n
g

(
L
e
v
e
l
1
)
,

1
4
4
D
u
c
t
w
o
r
k
s

,

1
3
6
D
r
a
i n
l a
y
i n
g
,

1
2
9
L
a
n
d
s
c
a
p
i n
g
,

1
2
5
A
s
s
t

S
c
a
f
f
o
l d
e
r

,

1
2
4
H
y
d

E
x
c
a
v
a
t
o
r

O
p
.

,

1
2
1
J
o
i n
e
r
y
,

1
1
5
C
e
i l i n
g

I
n
s
t
a
l l a
t
i o
n
,

8
6
G
u
t
t
e
r

I
n
s
t
a
l l a
t
i o
n
,

5
3
B
u
i l d
.

O
p
e
r
.

&

M
a
i n
t
e
.
,

4
8
C
h
e
m
i c
a
l
G
r
o
u
t
i n
g
,

3
7
P
r
e
-
S
t
r
e
s
s
i n
g

W
o
r
k
s
,

3
4
G
e
n
e
r
a
l
W
e
l d
e
r
,

3
3
L
i f
t

I
n
s
t
a
l l a
t
i o
n
,

3
3
B
a
c
k
h
o
e

O
p
e
r
a
t
i o
n
,

2
7
P
a
r
q
u
e
t

I
n
s
t
a
l l a
t
i o
n
,

2
6
B
l a
s
t
i n
g
,

2
6
F
o
r
k
l l i f
t

O
p
e
r
a
t
i o
n
,

2
5
A
i r

C
o
n
d
i t
i o
n

,

2
2
P
l a
s
t
e
r
b
o
a
r
d

C
e
i l i n
g
,

2
0
P
a
i n
t
i n
g
,

1
6
D
o
z
e
r

O
p
e
r
a
t
i o
n
,

1
6
0
500
1000
1500
2000
2500
3000
3500
Trade Skills

Social Problems
Health & Decease Problems
Foreign Labour Problems
Ref: Immigration, 2005


The Current Scenario of
Malaysian Construction Industry
19
Social Problems
a) Currently 75 foreign workers out of 100 construction
workers
b) There are 318,000 foreign workers in Malaysian
Construction Industry
Let say one foreign worker gain RM400 per month;
RM400.00 x 12 months = RM5,000 per year,

318,000 x RM5,000 = RM 1.59 billion per year
It shows the high outflow of Ringgit
Construction Waste

The Current Scenario of
Malaysian Construction Industry
Ref: UKM, 2005
Concrete
14%
Soil & Sand
28%
Timber
45%
Brick
3%
Steel
7%
Roof tiles
1%
Others
2%
Sumber: Lestari, UKM 2005
MAJOR CAUSES OF QUALITY FAILURES
IN CONSTRUCTION
45%
2%
5%
7%
14%
27%
Construction
Quality
Building Design
Material Quality
Kesesuaian
rekabentuk
Material Failure
Others

The Current Scenario of
Malaysian Construction Industry
Quality Complaints
Sumber: KPKT
Usage
Promoting Industrialized Building Systems (IBS)
Simplifying Construction
FIGURE 4.3 - Knowledge in Industrialised Building
Systems (IBS)
34%
66%
% GOOD % POOR
IBS Survey 2005 Survey on the Malaysian Architects Experience in IBS Construction.
SO WHAT IS
CONSTRUCTION
ACTUALLY??
DIRTY
DIFFICULT
DANGEROUS
SOLUTION?:
CHANGE FROM THIS
TO THESE.






IBS IN MALAYSIA.
IBS is not new in the Malaysian construction industry,
particularly the usage of steel structures and pre-cast concrete
for the construction of bridges, drains and other infrastructure
projects.

Nevertheless, usage of IBS in the Malaysian building industry is
still very low if compared to the conventional methods.


IBS IN MALAYSIA.
The industry prefers to utilize the relatively cheap supply of
foreign workers to perform the labour-intensive construction
activities.; and at the expense of quality, speed and the
environment.

However, the cheap rates and abundant supply of labour would
not last forever, and any disruption to the supply would generate
huge problems to the industry


IBS IN MALAYSIA.
In going global, it is necessary for the local players to be efficient
and equipped with the relevant technology and experience.

Therefore, since 1998, CIDB has been actively promoting the use
of IBS in the Malaysian construction industry.

IBS Roadmap 2003-2010 was formulated to effectively
coordinate the industry towards industrialization; concentrating
on the usage of IBS in the building industry.
29
Industrialised Building System (IBS)
In 1966 the two pilot projects started by using IBS
concept. Namely?
i) Pekeliling Flat, Kuala Lumpur
ii) The Rifle Range Flat, Penang
In 1981-1993 PKNS acquired pre-cast concrete technology
from Praton Haus International, Germany to built housing
project
IBS IN MALAYSIA.
30
IBS in Malaysia
Industrialised Building System (IBS)
KLCC
Pekeliling Flats
LRT Station
KL Tower
Characteristics of IBS
The characteristics of IBS are :
1) Industrial production of components though
prefabrication, OR
2) Highly mechanised in-situ processes i.e. permanent steel
formworks, tunnel forms, etc.
3) Reduced labour during prefabrication of components and
site works.
4) Modern design and manufacturing methods involving
Information Technology i.e usage of Computer Aided design
(CAD) and Computer Aided Manufacturing (CAM).
5) Systematic Quality Control i.e ISO 9000 principles.
6) Open Building Concept i.e permitting hybrid applications,
and adaptable to standardization and MC.

All of the five characteristics are equally important to
ensure the achievement of the proven benefits of IBS. As
such, all systems need to possess all of the above in order
to be accepted as part of IBS.

Benefits of IBS
BENEFITS OF IBS
1) Low site workers requirement due to simplified
construction methods

2) Quality-controlled and highly aesthetic end products
through the processes of controlled pre-fabrication
and simplified installations
36
3) Reduction of construction materials at sites through
usage of pre-fabricated components

4) Reduction or elimination of conventional timber
formworks, replaced by pre-fabricated components
and alternative moulds with multiply-usage capability
37
BENEFITS OF IBS
5) Reduction of elimination of props due to the absence
of conventional timber props and the usage of pre-
fabricated components

6) Reduction of construction waste with the usage of the
standardized components and less in-site works
38
BENEFITS OF IBS
BENEFITS OF IBS
7) Cleaner sites due to lesser construction waste

8) Safer construction sites due to the reduction of site
workers, materials and construction waste
39
BENEFITS OF IBS
9) Faster completion of construction projects due to the
usage of standardized prefabricated components and
simplified installation processes

10) Overall, a cheaper total construction costs, made
possible due to all of the above
40
Types of IBS
42
In general, the construction method can be classified
into 4 categories :
a) Conventional Method
b) Cast-in situ
c) Composite Method
d) Fully prefabricated
Method b,c and d can be classified as non-conventional
methods and all types of IBSs are categorized under these
three
43
The construction method can be classified into 4
categories :
Construction Methods
Conventional Non Conventional
Cast in-situ Composite Fully Prefabricate
On site Off site
Precast Concrete
Load Bearing
Block
Sandwich Panel Steel Frame
Frame Panel Box
FIVE COMMON TYPES OF IBS
Based on the structural aspects of the systems, IBS can be divided
into five (5) common types :
Type 1 : Pre-cast Concrete Framing, Panel and Box Systems
Type 2 : Steel Formwork Systems
Type 3 : Steel Framing Systems
Type 4 : Prefabricated Timber Framing Systems
Type 5 : Block work Systems
1. Precast Concrete framing, panel, box
systems
PC columns, beams, slabs, 3d-components (balconies, staircases, toilets,
lift chambers, box girders, etc)
2. Steel formworks systems
Tunnel forms, beams and column moulding forms, permanent steel
formworks (metal decks), etc
3. Steel frame systems
Steel beams and columns, portal frames, roof trusses, etc
4. Prefab timber frame systems
Timber frames, roof trusses, etc
5. Block work systems
Interlocking concrete masonry unit, lightweight concrete
blocks, etc
50
e.g.: Interlocking concrete masonry unit (CMU),
lightweight concrete blocks
Case Study 1

IBS STRUCTURES: STEEL
FORMWORK SYSTEM FOR
WALL, BEAM , COLUMN &
SLAB
2 TOWERS 30 STOREYS
(APARTMENTS & OFFICES)
CONSTRUCTION FOR IBS
STRUCTURES: 6 MONTHS
NORTHAM CITY, PENANG
Case study 2

IBS STRUKTUR: LIGHTWEIGHT
CONCRETE BLOCK &
PRECAST CONCRETE WALL;
PRECAST HALF SLAB
7 BLOCK CONSIST OF 100
UNITS, 3-4 STOREYS
CONSTRUCTION FOR IBS
STRUCTURE: 4 MONTHS
TEACHERS QUARTERS, LUKUT, N.SEMBILAN
Case Study 3

CIDB MALAYSIA
IBS STRUCTURES: PRECAST
HALF SLABS, PRECAST
COLUMNS, BEAMS AND WALLS
9,600 m2, 6 BLOCK WORKSHOPS
IBS STRUCTURES: 3 MONTHS
AKADEMI BINAAN MALAYSIA, SINTOK, KEDAH
Case Study 4

KEMENTERIAN KESIHATAN
620 BEDS
IBS STRUCTURES : HYBRID
STEEL FRAMING + PRECAST
SLABS, LIGHTWEIGHT
CONCRETE BLOCKS.
130,000 m2, 9 STOREYS
IBS STRUCTURES : 4 MONTHS
HOSPITAL SERDANG, SELANGOR
Case Study 5

SETIA PUTRAJAYA SDN BHD
658 UNITS
IBS STRUCTURES : PRECAST
WALL, SLABS WITH TOTAL
NUMBERS OF PC PANELS
= 19,000
IBS STRUCTURES : 10 MONTHS
APARTMENTS, PRISINT 9, PUTRAJAYA
How?
PRECAST PILE CAP
PRECAST GROUND BEAM
EXAMPLE : TEACHER QUARTERS
MANUFACTURE
TRANSPORTED
INSTALLED
INSTALLATION WORKS
EXAMPLE : TEACHER QUARTERS
EXAMPLE : TEACHER QUARTERS
PEMBINAAN AKADEMI BINAAN, SINTOK
PEMBINAAN STRUKTUR BANGUNAN : 3 BULAN
Problems Faced
64
Industrialised Building System (IBS)
Only 15% contractors using IBS, Why?
i) Lack of Expertise / Lack of Experience
ii) Cost
65
1. Lack of Expertise / Lack of
Experience
a) Lack of experience practicing/designing IBS by the
consultants/contractors/clients
b) Short of experience workers in the manufacturing and
installation works (most of them are foreign workers)
c) Defect works by previous pre cast system (close
system)
d) QS lack of experience pricing the IBS projects (most
of them not pricing the total cost of project)
66
Industrialised Building System (IBS)
2. Cost
Only 15% contractors using IBS, because the low
labour cost in this country is the root causes
Labour cost is cheap, so why IBS?
Modular
Coordination
MC is an international system that standardises the
measurements in buildings

Based on ISO standards, it is formulated to coordinate
the positions and dimensions of components and
spaces in building designs

68
MS 1064 and ISO standards specify that MC is a
concept of coordination of dimension and space, in
which buildings and components are dimensioned and
positioned in terms of basic units or modules, known as
1M which is equivalent to 100mm, and this is accepted
not only by countries implying ISO standard but also
internationally
69
Facilitates cooperation between building designers,
manufacturers, distributors, contractors and authorities

In the design work, enables buildings to be dimensioned
so that they can be erected with standard components
without undue restriction on freedom of design

Optimizes the number of standard sizes of building
components
70
Permits a flexible type of standardisation, which
encourages the use of a limited number of standardised
building components for the construction of different
types of building

Encourages interchangeability of components as mush
as possible, in whatever materials, forms or methods of
manufacture
71
Simplifies site operations by rationalising setting out,
positioning and assembling of building components

Ensures dimensional coordination between installation
(e.g. equipment, storage units, other fitted furniture) as
well as with the rest of the building
72
IBS PROJECTS IN MALAYSIA
73
74
Challenges in IBS
A pre-requisite for IBS is the adoption of MC by all
parties from the submitting technical consultants to the
approving authorities

In Malaysia, MC is hardly used in building design

76
The reality in our context is that most building
specialists still apply measurements in terms of feet
e.g.18-footer house instead of 6-meter house

For this system to be successfully utilised, both public
and private sectors would need to play their roles in
educating the local construction industry players
77
Aside from voluntarily changing in mind set, there must
be some push factors to catalyse the shift in mindset

Incentives and regulatory requirements for the
introduction and adoption of IBS should be the next
concrete plan of action to be spearheaded by CIDB
78
Processi
ng
of steel
Assembly
of floor
frame
Assembly
of
ceiling
frame
Assembly of
sidewall
frames
Assembly
of
structural
unit
Attachment
of exterior
walls
Applicatio
n of
insulators
Attachmen
t of
interior
walls
Incorporatio
n of kitchen
facilities
Incorporation
of bath and
sanitary
facilities
Final
inspection
Packin
g
Shipme
nt
Deliver
y
Installati
on
Major production process
- Manufactured house (Sekisui)
Inside a Modular Factory
Assembly of floor frame
Assembly of structural unit
Attached of
interior walls
Incorporate of sanitary
facilities / kitchen facilities
Packing
Delivery & Assembly
Completion