Chapter 2 - New PDF

TECHNOLOGY OF
IBS
BFP40603 – INDUSTRIALISED BUILDING SYSTEMS (IBS)
CONTENT
• Types of IBS
• Precast Concrete Framing, Panel and Box
System
• Formwork Systems
• Prefabricated Steel Framing Systems
• Prefabricated Timber Framing Systems
• Blockwork Systems
• Innovative
• Facilities and infrastructures
Learning outcome:
• Identify and understand the components type of IBS such as
Precast Concrete Framing, Panel and Box system; Formwork
System, Steel Framing System; Prefabricated Timber
Framing System; Blockwork System and Innovative.
Earliest classification of IBS (Junid, 1986)
Frame or post and beam panel system Box system
system
Column and beam - main Loads are distributed Three-dimensional modules

structure member (support through large floor and wall or boxes for fabrication of
all the building weight) panels where walls support habitable units that are
Walls - light and easy the building weight. capable of withstanding load
to install Applicable to buildings which from various directions due
Concrete panels - flooring require large number of to their internal stability
walls-apartment house, hotel
and hospital.
Not suitable to buildings with
large spans or many stories
Example of box system – toilet/bathroom pod
Example of box system – toilet/bathroom pod
Toilet/Bathroom pod production in the factory

Example of box system – modular house
Installation of module at site

Module 1
Module 2
This house consists of two modules/unit – each module/unit is

manufactured and transported individually
Example of box system – modular house (2-storey)
Please watch this video to understand more about modular
house installation
https://www.youtube.com/watch?v=5xgbPo1vEWY
Current classification of IBS by the CIDB:
IBS Types
Precast concrete Formwork Blockwork Innovative

framing, panel system system product system
and box system
Prefabricated Prefabricated
steel framing timber framing
system system
1) Precast concrete framing,
panel and box system
The most common group of IBS

products is the pre-cast concrete
elements, such as, pre-cast
concrete column, beams, slabs,
walls, “3-D” components
(examples, balconies, staircases,
toilets, lift chamber, refuse
chambers), lightweight pre-cast
concrete, as well as permanent
concrete formwork
Precast concrete framing system
Precast
beam
Precast
column
Wall is
constructed
using CMU
(bricks)
Preparing M&E for precast concrete wall panel
Case study – Precast concrete framing and
wall (Please refer appendix)
• College Inti
• Amway building
• KLCC car park
• Kem Kementah Kuala Lumpur – wall panel
• Single storey terrace house – wall panel
2) Formwork system
• Considered as one of the “low-level” or the “least

prefabricated” IBS, as they generally involve site casting
• High quality finishes, fast construction with less site labour and
material requirement.
• These include tunnel forms, tilt-up systems, beams and
columns moulding forms.
• Onsite fabrication - the walls and complete building are cast
on-site, using specially designed and reusable formwork
moulds.
• The formwork may be made from plastic, steel etc.
• The claim to prefabrication lies in the manufacture of the
moulds, into which the concrete is poured.
Installation of formwork system at construction site.
Case study
• PRIMA-1 (refer appendix)
Please watch this video:

https://www.youtube.com/watch?v=KoEyT_RXGeE
3) Prefabricated steel framing
system
Commonly used with pre-cast
concrete slabs, steels column and
beams, steel framing systems have
always been the popular choice and
used extensively in the fast-track
construction of skyscrapers.
Recent development in this type of
IBS includes the increased usage of
light steel trusses consisting of cost-
effective profiled cold-formed
channels and steel portal frame
systems as alternatives to the heavier
traditional hot-rolled sections.
4) Prefabricated timber
framing system
Products - timber building
frames and timber roof trusses.
While the latter are more
popular, timber building frame
systems also have its own niche
market: offering interesting
design from simple dwelling
units to buildings requiring high
aesthetical values such as
chalets for resorts
Case study
• Glulam Gallery
5) Blockwork system
• 2 types - Interlocking
concrete masonry units
(CMU) and lightweight
concrete blocks.
• Simplify the traditional
brick-laying tasks
• Usually, the block is
designed as a load bearing
wall system, in which the
bricklaying work does not
require mortar (dry system),
and the component can
easily be installed like a
‘Lego’ system.
Proven Holdings
To strengthen the block to allow for load
bearing, reinforcing steel was put inside the
cavity and filled with concrete.
Case study
• Bandar Enstek Secondary School

• Rumah Mesra Rakyat 1Malaysia
6) Innovative
This category refers to the various pre-fabricated materials that

have entered the market, which include gypsum, wood wool,
polymer, fibreglass, glass and aluminium-based IBS components.
There are several types of construction method that are classified

under this category. Examples are in the next slides
Example of innovative type of IBS - video in the next slide
Polystyrene Mesh reinforcement
Concrete is sprayed onto the wall
Source: FB IBS Concrete Panels Sdn Bhd

Another example of innovative type of IBS -Wet wall system
Video: Ajiya IBS Green (Enduroframe)

IBS FACILITIES AND INFRASTUCTURE
Typical Industrialised Building System (IBS) Construction Process (Adapted from Hamid, 2010)
Production
facility
Equipment
at site
Transportation
1) Producing the components within controlled environment whether offsite or on-site;

2)Delivery of component to the construction site or workplace; and
3) Installation of components and ancillary site works.
1) Production facility
• Plant -
• Equipment
• Skilled/semi-skilled/non-skilled worker
• Management resources
>> initial capital investment is relatively expensive - such huge

investment can only be breakeven if there is sufficiently high
demand for the products. On the other hand, a temporary
casting yard or factory can be established at the project site in
order to minimized the transportation costs (Peng, 1986)
Batching plant
Overhead crane
Precast concrete mould &

casting bed
Facilities at precast concrete fabrication yard
Concrete
bucket
Mixer truck
Worker
Concrete vibrating
machine
Precast concrete fabrication yard

Storage/stacking of precast component
(slab) at yard – stacked horizontally
Stacking of precast concrete wall (must be

stacked vertically)
Bending machine used to bend the steel bar
Precast concrete fabrication yard

QA/QC checking during production
Forklift for transportation

Storage facility
Blockwork manufacturing
Blockwork manufacturing (automatic - no manpower is needed)
Prefabricated steel framing factory
Prefabricated timber framing factory
2) Transportation
• Large truck, lorry

• It is found that casting a large panel system can reduce
labour cost up to 30 percent. However, 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 (Peng, 1986)
Transportation of wall panel – the panels should be arranged diagonally on the
truck
Transportation of precast slabs – the slabs should be arranged horizontally on
the truck (same goes to beam and column)
3) Equipment at site
• For the purpose of erecting and assembling pre-cast panel

into their position, heavy crane is required especially for
multi-story building.
• Crane, other equipment and tool
Crane lifting precast component
References
• Thanoon et al, THE ESSENTIAL CHARACTERISTICS OF

INDUSTRIALISED BUILDING SYSTEM, International
Conference on Industrialised Building Systems, Kuala
Lumpur, Malaysia, 10-11 September, 2003

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TECHNOLOGY OF

Column and beam - main Loads are distributed Three-dimensional modules

Toilet/Bathroom pod production in the factory

Installation of module at site

This house consists of two modules/unit – each module/unit is

Precast concrete Formwork Blockwork Innovative

The most common group of IBS

• Considered as one of the “low-level” or the “least

• PRIMA-1 (refer appendix)

Please watch this video:

• Bandar Enstek Secondary School

This category refers to the various pre-fabricated materials that

There are several types of construction method that are classified

Polystyrene Mesh reinforcement

Concrete is sprayed onto the wall

Source: FB IBS Concrete Panels Sdn Bhd

Video: Ajiya IBS Green (Enduroframe)

1) Producing the components within controlled environment whether offsite or on-site;

>> initial capital investment is relatively expensive - such huge

Precast concrete mould &

Precast concrete fabrication yard

Stacking of precast concrete wall (must be

Bending machine used to bend the steel bar

Precast concrete fabrication yard

Forklift for transportation

• Large truck, lorry

• For the purpose of erecting and assembling pre-cast panel

• Thanoon et al, THE ESSENTIAL CHARACTERISTICS OF

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