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INDUSTRIALISED BUILDING SYSTEM FORMATION

SCHEDULING FOR PUBLIC BUILDINGS

ALLAN TAY ENG MIAN

A project report submitted in partial fulfillment of the

requirements for the award of the Degree of

Master of Science (Construction Management)

Faculty of Civil Engineering

Universiti Teknologi Malaysia


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PPSSZZ 1199::1166 ((PPiinndd.. 11//9977))UUNNIIVVEERRSSIITTII TTEEKKNNOOLLOOGGII MMAALLAAYYSSIIAA

BORANG PENGESAHAN STATUS TESIS

J UDUL : INDUSTRIALISED BUILDING SYSTEM FORMATIONSCHEDULING FOR PUBLIC BUILDINGS

SESI PENGAJ IAN : 2005 / 2006

Saya

(HURUF BESAR)

mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di PerpustakaanUniversiti Teknologi Malaysia dengan syarat-syarat kegunaan seperti berikut:

1. Tesis adalah hakmilik Universiti Teknologi Malaysia.2. Perpustakaan Universiti Teknologi Malaysia dibenarkan membuat salinan untuk tujuan

pengajian sahaja.3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara

institusi pengajian tinggi.4. ** Sila tanda ( )

SULIT (Mengandungi maklumat yang berdarjah keselamatan ataukepentingan Malaysia seperti yang termaktud di dalam

AKTA RAHSIA RASMI 1972)

TERHAD (Mengandungi maklumat yang TERHAD yang telah ditentukanoleh organisasi/badan di mana penyelidikan dijalankan)

TIDAK TERHAD

Disahkan oleh

(TANDATANGAN PENULIS) (TANDATANGAN PENYELIA)

Alamat Tetap:

PROF. MADYA DR. ABDUL KADIR

ALLAN TAY ENG MIAN


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We hereby declare that I have read this project and in my opinion this project is

sufficient in terms of scope and quality for the award of the degree of Master of

Science (Construction Management) by taught course.

Signature :

Name of Supervisor I : ASSOC. PROF. DR. ABDUL KADIR

MARSONO

Date : April 2006

Signature :

Name of Supervisor II : DR. MASINE MD TAP

Date : April 2006

Signature :

Nameof Supervisor III : ASSOC PROF DR AHMAD


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I declared that this project report entitled INDUSTRIALISED BUILDING

SYSTEM FORMATION SCHEDULING FOR PUBLIC BUILDINGS is the result

of my own research expect as cited in references. This report has not been accepted

for any degree and is not concurrently submitted in candidature of any degree.

Signature :

Name : ALLAN TAY ENG MIAN

Date : APRIL 2006


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Especially to my beloved family


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ACKNOWLEDGEMENT

The author wish to express his sincere gratitude to all who have helpeddirectly or indirectly in his Masters Project research work, and a big thank you

especially to project supervisor, Associate Professor Dr. Abdul Kadir Marsono, for

his passionate assistance, guidance and concern. With his invaluable advice and

superb guidance, the author has successfully completed his Masters Project. It is

indeed a true honour and privilege for being able to work under the supervision ofsuch a dedicated and enthusiastic lecturer. Thank you Dr!

Special thanks are due to Dr. Masine Md Tap and Associate Professor Dr.

Ahmad Mahir Makhtar for their close guidance and assistance throughout the process

of carrying out the research work. Besides, the author would like to thank all parties

that have been so kindly in giving invaluable information and data to the author.

Special thanks are also due to Ir. Ihsan B. Atan, Construction Manager of Gerbang

Selatan Bersepadu Project, Pn. Naemah Bt. Abd. Jamil, JKR State Assistant

Director of Education Project, directors, project managers, supervisors and engineers

of Eastern Pretech (Malaysia) Sdn. Bhd., Precast Product Sdn. Bhd., Takenaka

Corporation (Malaysia) Sdn. Bhd., Jeks Engineering Sdn. Bhd., Pilot Construction

Sdn. Bhd. and staffs at JKR Johor State Headquarters for their invaluable help while

the author was carrying out the research work.


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ABSTRACT

The construction industry plays a major role in our countrys economicgrowth. However, the industry is not without weaknesses. The challenges often

occur in the area of productivity, efficiency of work, quality of work and the delivery

of work. The intensive use of foreign unskilled workers, low technology equipments

and out-of-dated construction methods, have eventually caused low productivity and

inefficiency of work at construction site. IBS is one of the improved buildingsystems that are being introduced in the construction industry, to achieve the target

of faster completion with mass production of the building elements in places out of

its final location in a building. A study was conducted to analyse ways to improve

the implementation of IBS in terms of IBS scheduling at site for public buildings

especially schools in our country. A comparison between the scheduling of both theconventional method and the proposed IBS method was carried out using Microsoft

Project. The critical outputs in managing the scheduling of project such as time,

labour productivity and task factor were clearly analysed. Types of lifting system

were identified to ensure highest productivity and efficiency of work at site. Lastly,

comparative check of proposed new conceptual school building utilising standardIBS components with Uniform Building By-Law 1984 were also carried out in this

study.


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vi

ABSTRAK

Industri pembinaan memainkan peranan yang penting di dalamperkembangan ekonomik negara kita. Walau bagaimanapun, industri ini tidak

terkecuali daripada kelemahannya. Cabaran pada kebiasaannya berlaku dari sudut

produktiviti, keberkesanan kerja, kualiti kerja dan penyiapan projek. Penggunaan

buruh asing yang tidak berkemahiran, penggunaan kelengkapan yang berteknologi

rendah dan teknik kerja yang sudah ketinggalan zaman telah menjurus kepadaproduktiviti dan keberkesanan kerja yang rendah di tapak pembinaan. IBS

merupakan salah satu sistem bangunan yang baru dan terkini yang diperkenalkan

dalam industri pembinaan tempatan, untuk mencapai sasaran perlaksaan projek yang

lebih pantas dengan penghasilan komponen bangunan di luar tapak pembinaan. Satu

kajian telah dilakukan untuk menganalisis langkah-langkah dalam mempertingkatkanaplikasi IBS dari segi penjadualan IBS di tapak untuk bangunan awam seperti

pembinaan sekolah di negara kita. Satu perbandingan di antara penjadualan untuk

kaedah konvensional dan cadangan kaedah IBS telah dilakukan dengan

menggunakan Microsoft Project. Output kritikal dalam pengurusan penjadualan

projek seperti masa, produktiviti buruh dan faktor kerja telah dianalisis dengan teliti.Jenis sistem kren yang ideal telah dipilih untuk memastikan produktiviti dan

keberkesanan kerja yang optimum di tapak pembinaan. Akhirnya, perbandingan telah

dibuat antara cadangan bangunan sekolah yang berkonsep baru dengan menggunakan


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TABLE OF CONTENTS

CHAPTER DESCRIPTION PAGE

TITL E i

DECLARATION ii

DEDICATION iii

ACKNOWLEDGEMENT iv

ABTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xii

LIST OF FIGURES xiii

LIST OF APPENDIXES xvii

CHAPTER 1 INTRODUCTION

1.1 Introduction 1

1.2 Problem Statement 4


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viii

CHAPTER 2 LITERATURE REVIEW

2.1 Introduction 92.2 Industrialised Building System (IBS) 102.3 Typical classification of IBS 12

2.3.1 The frame system 14

2.3.2 Panel system 192.3.3 Box system 22

2.4 Classification for Types of IBS Used in Malaysia 242.5 The Benefits of IBS 252.6 Modular Coordination 272.7 Just-In-Time (JIT) Management in the Precast

Concrete Construction 29

2.8 Experiences Of Other Countries in IBS 322.8.1 The United States of America (U.S.A.) 32

2.8.2 Japan 33

2.8.3 Netherlands 342.8.4 Singapore 35

2.8.5 Thailand 38

2.8.6 Britain 40

2.8.7 Denmark 41

2.9

Malaysias own experience in IBS 412.10 Sequence of conventional construction method 452.11 Sequence of construction for IBS method 472.12 Scheduling of IBS components on site 49


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CHAPTER 3 METHODOLOGY

3.1 Introduction 56

3.2 First stage: Identification of research topic and

scope of study 56

3.3 Second stage: Data collection 58

3.4 Third stage: Results and analysis 623.5 Fourth stage: Make conclusion 63

CHAPTER 4 DATA ANALYSIS AND DISCUSSION

4.1 Introduction 64

4.2 Background Study 65

4.3 Case Studies 66

4.3.1 Construction site: Jusco Tebrau City, Johor 664.3.2 Construction site: Subang USJ Mydin

Wholesalers Hypermarket 67

4.3.3 Construction site: Kidney Dialysis Centre,Kuching 69

4.3.4 Precaster: Eastern Pretech (Malaysia)Sdn. Bhd. 70

4.3.5 Precaster: Precast Product Sdn. Bhd. 714.3.6 Precast Specialist Contractor: Takenaka

C i (M l i ) Sd Bhd 71


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4.5 Results of Analysis 82

4.6 The Critical Outputs in Managing the Scheduling

of Project 87

4.6.1 Time factor 87

4.6.2 Labour productivity 92

4.6.3 Task factor 96

4.7 Lifting systems 99

4.8 Comparative check of proposed IBS school design

with Uniform Building By-Laws 1984 103

4.8.1 Part III: Space, Light and Ventilation Clause 38 (1) - Width of footway 104

4.8.2 Part III: Space, Light and Ventilation Clause 39 (3) Natural Lighting andVentilation 104

4.8.3 Part III: Space, Light and Ventilation Clause 39 (4) Natural Lighting andVentilation 104

4.8.4 Part III: Space, Light and Ventilation Clause 43 (a) Minimum dimensions oflatrines, water-closets and bathrooms 105

4.8.5 Part III: Space, Light and Ventilation Clause 44 (4) Height of rooms inresidential buildings, shophouses, schools, etc 105

4.8.6 Part V: Structural requirements Clause 53 (1), (2) Building materials 105

487 PartV:Structural requirements


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CHAPTER V CONCLUSIONS AND RECOMMENDATIONS

5.1 Conclusion 108

5.2 Recommendations 112

REFERENCES 115

APPENDIXES 120 - 135


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xii

LIST OF TABLES

TABLE NO. TITLE PAGE

2.1 Building system classification according to relative

weight of component 13

2.2 Prefabricated housing market share in Japanese FiscalYear 1999 (April 1999-March 2000). 34

4.1 The proportion of bays for the proposed conceptual school 79

4.2 The summary for the comparisons of overall construction

period for the conventional Cast-In-Situ method and

precast IBS method 86

4.3 The approximate duration for the installation for each

component 88

4.4 The total components used in the assembly of the

proposed conceptual IBS school 97

4.5 A summary of the installation of precast components


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xiii

LIST OF FIGURES

FIGURE NO. TITLE PAGE

1.1 The scenario of our construction industry today. 5

2.1 Frame System 12

2.2 Panel System 12

2.3 Box System 12

2.4 Examples of frame systems for industrialised buildings 14

2.5 A typical rectangular frame that consists of two precastconcrete columns and a precast horizontal beam 15

2.6 Another typical rectangular frame, which consists of two

columns and a horizontal beam, prefabricated using steel

sections 15

2.7 Examples of frame system for multi-storey buildings 16

2.8 Two examples of frame system for public buildings 17


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2.12 The support of slabs along edges on bearing wall panels 20

2.13 Examples of the application of hollow core slab as slab

panels in the building construction 21

2.14 Application of panel system as interior walls 22

2.15 The use of wall panels in the building construction 22

2.16 Arrangement of box units into position onsite 23

2.17 The sequence of installation of box system onsite 24

2.18 The JIT principle in the construction industry scenario 31

2.19 Examples of innovative IBS components produced in

Singapore 37

2.20 The application of PLP in the construction industry in

Thailand 39

2.21 The sources of IBS in Malaysia according to the origin

of countries 42

2.22 Sequence of activities of IBS construction method 48

3.1 The flow chart of the research methodology 57

4.1 Jusco Tebrau City during construction period 67


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4.6 Structural overview of the proposed conceptual school

(view as per level only) 76

4.7 The allocation of classrooms for each 5 bays with the two

offices in between each classroom 78

4.8 The proposed conceptual school as generated in 3D

modelling using ACAD software (Perspective View) 80


modelling using ACAD software (Front View) 80


modelling using ACAD software (Back View) 81

4.11 The overall proposed conceptual school as generated in

3D modelling using ACAD software 82

4.12 The scheduling of conventional construction method

using Microsoft Project 83

4.13 The scheduling of IBS method using Microsoft Project

shows a significant time saving of up to 135 days compared

to the conventional method 85

4.14 The time frame for the installation sequence of precast

concrete elements at site 90

415 Delivery andunloadingof structural componentswill only


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4.18 The lifting apparatuses used by the crane 99

4.19 The application of four-point picks in the construction

of the proposed IBS method school 101


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xvii

LIST OF APPENDIXES

APPENDIX TITLE PAGE

A Gantt Chart for Conventional Method 120

B Gantt Chart for IBS Method 122

C 100 Metric Tonne Crane Specification 124

D Gantt Chart for four-point picks scheduling 128

E Gantt Chart for three-point picks scheduling 130

F Gantt Chart for two-point picks scheduling 132

G Gantt Chart for single-point picks scheduling 134


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CHAPTER I

INTRODUCTION

1.1 Introduction

The construction industry plays a major role in our countrys economic

growth. According to CIDB (2000), over the last 20 years, the construction industry

in Malaysia has been consistently contributing between 3% to 5% of the nationalGDP. This shows how much the construction sector has been contributing towards

the economic growth of our country. According to Wang (1987), the construction

industry can serve as a barometer indicating the nations economic conditions. Brisk

construction activities generally show that the nations economy is booming and

progressing well, and whereas sluggish construction activities show that the

countrys economy condition is under depression.


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Construction industry basically consists of various processes, involves many

parties and different stages of work. It involves the participation of various parties

from various sectors in order to ensure the efficiency of the construction work carried

out. The efficiency and success of construction development and activities depends

heavily on the quality of managerial and organizational performance plus the

effective co-ordination through good teamwork from the different parties. It is

therefore obvious that the development of the construction industry can only be

achieved if every team members play effective roles in their work.

The construction industry involves the participation of seven various sectors.

This includes the Client/Developer Sector, the Consultant Sector which includes

project management consultants, planners, architects, engineers, quantity surveyors,

land surveyors and other specialist consultants, the Contractor Sector which also

includes the main contractor, specialist and nominated sub-contractors, The Material

and Equipment Supplier Sector, Manpower Sector, which includes unskilled,semi-skilled and skilled workers, The Finance Sector which involves banks, finance

and credit companies and lastly, the Approving Sector, which involves the local

authorities, state and federal government. The efficiency and productivity of the

industry depends largely on how the various sectors can jointly co-operate and try to

understand each others needs and problems.

However, the industry is not without weaknesses. More often than not, the


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delivery of work.

According to Ismail (2001), in the 7th Malaysia Plan, 800,000 units of houses

has been planned and out of that figure, 585,000 units or 73.1% were planned for low

and medium cost houses. The disappointing fact is that, only 20% of completed

houses were reported throughout the nation, despite numerous incentives and

promotions to encourage developers to venture into such housing category. What has

gone wrong?

Waleedet al. (2003) reported that, the announcement of the 8th Malaysia Plan

with the planning of 600,000 to 800,000 low and medium houses throughout the

nation is indeed welcoming news to the population of Malaysia, especially to the

middle and low income groups. However, it is undoubtedly an uphill task to

accomplish such target with the current conventional building system currently

practiced widely by the construction industry in our country.

Therefore, the former system must be reviewed and better still replaced with

a new system, which has better advantages in terms of improving productivity,

indoor quality, improvement of work durability and efficiency and overall cost

reduction. The introduction of the Industrialised Building System (IBS) with the

promise of improving productivity rate, lowering construction costs and meeting the

gro ing demand for affordable ho sing is indeed elcoming ne s to o r co ntr s


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1.2 Problem Statement

With the ongoing construction trend in Malaysia, that is still very

comfortably using labour intensive and low technology methods of construction, this

has initially lead towards low productivity and inefficiency of work at construction

site. Moreover, with the Governments call for more affordable housing, the

construction industry has had to fulfil national housing and commercial needs which

has eventually led to devastating compromise in quality of work.

The highly dependency on unskilled and cheap foreign workers has definitely

contributed to low productivity of work, because although they may be cheap, but

they are not efficient and cause high wastage. The quality of work has also been

terribly affected due to unskilled working method. After completion defects,

structural failures and design inadequacies are some of the tell-tale sign of the current

construction scenario in our country. According to CIDB (2000), complaints made by

consumers through national media and to the authorities are some of the numerous

indications of low quality of work. At the end, these will lead to decreased quality of

life in uncomfortable and unfriendly environments. Figure 1.1 shows the scenario of

our construction industry today.


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Figure 1.1: The scenario of our construction industry today.

Based on Figure 1.1, we can see that our construction industrys highly

dependency on untrained labours has led to the high usage of unskilled and cheap

foreign workers. This has prompted the current construction industry to be labourintensive, due to the high usage of unskilled workers in the construction field. Taking

into account of the high usage of foreign unskilled workers at site, it is difficult for

the construction sector to achieve high productivity of work at site.

However, if we were to introduce trained workers into the construction

projects, we can achieve high productivity and efficiency of work, since the workers

are able to carry out the work at site skilfully and effectively. These skilled and

Untrained Labour Trained Labour

ConstructionProjects

Labour

Intensive

IBS Trained

Personal

FACTORY

- Lean / sustainable projects

- Manufactured buildings

- Not labour intensive


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that are less labour intensive.

Although the long-introduced Industrialised Building System (IBS) has

promised to solve and improved the current construction method and scenario in our

country, but the IBS method has been low in gaining popularity, partly due to lack of

awareness and coordination among the relevant parties. Currently, the level of usage

of IBS method is very low as compared to the conventional methods in building

construction. In spite of its many benefits, the different perceptions among the

construction players and practitioners towards its application in construction industry

has led to the low usage of IBS components in the construction industry.

Moreover, the benefits of IBS applications in the construction industry has

yet to be known and uncovered due to lack of research studies conducted in the

Malaysias construction perspective. Our local construction players are still in doubt

of the efficiency of IBS method of construction as compared to the conventional

method. The question to how much can the IBS method contributes towards reducing

the total construction period, the efficiency of the assembling and erection processes

at site and the production stage still lingers on and remain unanswered. At the end of

the day, the IBS method remains unknown and unfamiliar to the local construction

industry.

C rrentl p blic b ildings s ch as schools in Mala sia are still idel


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teachers, and thus providing a conducive studying environment to the students is

normally out of the question.

It is hoped that the precast technology can bring out the tremendous potential

towards productivity improvement as it encompasses aspects of standardisation,

highly controlled and quality precast components which complements the various

programs to increase productivity and quality control through the adoption of

Modular Coordination (MC) and Industrialised Building System (IBS).

1.3 Objectives of Study

The objectives of this study are as follows:

(i)

To achieve faster construction by reducing overall construction time, utilizingIBS method.

(ii) To propose a new conceptual school building using standard IBS components,replacing the existing JKR conventional school buildings.

(iii) To identify the generality for the processes in an IBS scheduling.(iv) To identify ways to integrate IBS method into the scheduling of school

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1.4 Scope of Study

The scope of this study is focused to building construction, especially

involving public projects such as school construction. The purpose of this study is to

determine whether the Industrialised Building System (IBS) can be implemented into

the construction of public projects in our country, especially in reducing the overall

construction period.


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CHAPTER II

LITERATURE REVIEW

2.1 Introduction

This chapter highlights the subject of Industrialised Building System (IBS),

its importance and contribution to the construction industry, both internationally and

locally in Malaysia, and also to elaborate in details the sequence of construction of

both IBS and conventional working method. This chapter will also review on the

concepts of Modular Coordination (MC), Just-In-Time principles, the scheduling of

IBS components at site, types of scheduling methods and will emphasize on the

scheduling of public buildings in Malaysia utilising IBS method.

This chapter will also explore the literature information that will later

illustrate the research methodology that will be carried out in the following chapter.


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2.2 Industrialised Building System (IBS)

According to Warszawski (1999), building system is defined as a set of

interrelated elements that act together to enable the designated performance of a

building. Industrialised Building System (IBS) is one of the improved building

systems that are being introduced to achieve the target of faster completion with

mass production of the building elements in places out of its final location in a

building.

Rollet (1986) also defined the word industrialising as to build on site with

elements or components produced by series in plants. An industrialised organisation

of building means that these components can be assembled together even though

they are produced on different plants as they have then to be compatible. Another

definition given by Trikha (1999), expounded that Industrialised Building System

(IBS) is a system in which concrete components, prefabricated at site or in factory

are assembled to form the structure with minimum in-situ construction.

Esa and Nuruddin (1998) also defined that an IBS is a continuum beginning

from utilising craftsmen for every aspect of construction to a system that make use of

manufacturing production in order to minimise resource wastage and enhance value

for end users.


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In this well-defined concept by Junid (1986), the software element includes

the whole system design, a complex process of studying the requirement of the endusers, market analysis and forecast, development and production of standardised

components, establishment of manufacturing and assembly layout and processes,

allocation of resources and materials and definition of a building designer conceptual

framework. In short, the software element provides a prerequisite condition to create

the best environment for industrialised building system to expand further.

Junid (1986) further elaborated that the hardware element are categorised into

three major groups. These include frame or post and beam system, panel system and

box system. The framed structures are defined as those structure that carry loads

through their beams and girders to columns and then to the ground whilst in panel

system, the load are distributed through large floor and wall panels. The box systems

include those systems that employ three-dimensional modules (or boxes) for

fabrication of habitable units that are capable of withstanding load from various

directions due to their internal stability.

In short, Industrialised Building System (IBS) is a construction method that

offers economisation of design, site work and materials, provides shorter

construction time, saving in labour, better quality control, immunity to weather

changes and the most importantly, the cost factor. It has been proven successful in

some countries, namely Finland, Denmark, Netherlands, Singapore, England and the

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2.3 Typical classification of IBS

There are various Industrialised Building Systems (IBS) used throughout the

world, and they can be classified into three major categories. According to Junid

(1986), the typical classifications are as follows:

(i) Frame or post and beam system(ii) Panel system(iii) Box system

Figure 2.1, Figure 2.2 and Figure 2.3 shows the concept of the system as

classified above. In the evaluation of the systems, various parameters such as the

industrialised process used, the transportation and erection problems, architectural

features and the sosio-economic problems must be considered.

Figure 2.1: Frame System (Junid, 1986) Figure 2.2: Panel System (Junid, 1986)

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However, Majzub (1977) commented that the relative weight of components

should be used as a basis for building classification. The factor of weight has a hugeimpact on the transportability of the components and also has influence on the

production method of the components and their erection method on site. This

classification by weight can help to distinguish between various basic materials used

in the production of the components, which by itself help to determine the

characteristics of the studied system. Table 2.1 shows building system classification

according to relative weight of component.

Table 2.1: Building system classification according to relative weight of component

(Majzub, 1977)

No General System System Production Material

Light weight frame Wood, light gage metals

Medium light weight frame Metal, reinforced plastics,

laminated wood

1 Frame system

Heavy weight frame Heavy steel, concrete

Light and medium weightpanel

Wood frame, metal frameand composite materials

Heavy weight panel (factory

produced)

Concrete

2 Panel system

Heavy weight panel (tilt

up-produced on site)

Concrete

Medium weight box (mobile) Wood frame, light gage

metal, composite

Medium weight box

(sectional)

Wood frame, light gage

metal, composite

Heavy weight box (factory

d d)

Concrete

3 Box system

(modules)

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2.3.1 The frame system

Frame structures may be defined as those structures that carry the loads

through their beams and girders to column and to the ground. Junid (1986) also

stated that, in such a system, the skeletal structures will help to reduce the number

and sizes of load carrying members. Their important feature is the capacity to

transfer heavy loads over large spans. For this reason, they are used in the

construction of bridges, parking lots, warehouses, industrial buildings, sport facilities

and so on. Figure 2.4 show examples of frame systems for industrialised buildings.

Figure 2.4: Examples of frame systems for industrialised buildings

(Construction Photos).

Warszawski (1999) mentioned that different variants of the structural scheme

allow for the most convenient partitioning of the frame into connected precast

elements Fore ample inat picalframes stem arectang larframeshallconsistof

15


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The frame structures on its own, forms only the skeleton of the building and

do not enclose the space. Therefore, infill elements such as prefabricated panels or

building the infill elements on site or both need to be put up to complete the system.

Figure 2.5: A typical rectangular frame that consists of two precast concrete columns

and a precast horizontal beam (Construction Photos).

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many bays as necessary, or upwards, for multi-storey buildings. Figure 2.7 show

examples of frame system for multi-storey buildings. Figure 2.8 shows two examples

of frame system for public buildings.

Proper attention is needed especially to their lateral stability either by

introduction of rigid connections at the corners, by bracing with diagonals, or by

attaching the multiframe to a rigid building component. Figure 2.9 show examples of

bracing for frame system at connection part.

Figure 2.7: Examples of frame system for multi-storey buildings (Construction

Photos).

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Figure 2.8: Two examples of frame system for public buildings: (a) multi-storey car

park; (b) office building (Warszawski, 1999).

(a)

(b)

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spans between supports. Figure 2.10 shows roof materials ready to be placed on the

roof frame of a typical frame system.

Figure 2.10: Roof materials ready to be placed on the roof frame of a typical frame

system (Construction Photos).

The modern skeleton structure, conventional or industrialised is the result of

rational use of materials of construction in the building. The great strength of new

building materials and the advancement in the construction technology have enabled

the frame system to span to a further distance and higher altitudes and thereby cater

to the increasing demands of this modern society.

This type of system is not very popular in the field of housing, although it isvery popular for large structures such as industrial and institutional buildings. The

advantage of the frame system is mainly in the interior flexibility, as large space can

be sed for different f nctions and can be easil changed or modified according to

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2.3.2 Panel system

According to Junid (1986), panel system may be defined as those structures

that carry the load through large floor and wall panels. The panels can be made in

various forms and materials and are normally prefabricated at factory. Depending on

the scale of projects, some panels may be fabricated at site for easy transportation.

Concrete panel systems are extensively used in Europe for high rise building

for ease of construction purpose. In Malaysia, this system is slowly gaining

popularity in terms of high rise flats and low rise buildings. Other panel systems

available are as such wood, plastic, light weight metal and ferrocement materials.

Figure 2.11 shows panel system solutions applied to a typical residential building.

`

(a) (b)

(c) (d)

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Slabs are usually supported along edges on bearing walls or beams in the

application of panel system in the construction of the building. The application of

this system offers advantages in terms of easy manufacturing even under field

conditions, relatively economical in terms of concrete and steel usage, and most

importantly, do not require concrete topping or special structural connections to

ensure a common action of adjacent panels. Figure 2.12 shows the support of slabs

along edges on bearing wall panels.

Figure 2.12: The support of slabs along edges on bearing wall panels: (a) view; (b)

section; (c) moment connection; (d) with temporary support

(a)

(b) (c) (d)

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Figure 2.13: Examples of the application of hollow core slab as slab panels in the

building construction (Construction Photos).

The usage of panel system in the construction of interior walls and exterior

walls offer speed of construction in many ways. Figure 2.14 shows application of

panel system as interior walls. According to (Warszawski, 1999), wall panels

provides space enclosure, thermal insulation, sound isolation, exterior finish, housing

of windows, electrical conduits, and fixtures and structural support for floor slabs.

The exterior appearance of the wall panel is a very important architectural

consideration, and sometimes the main reason for the selection of a prefabricated

system. Figure 2.15 shows the use of wall panels in the building construction.

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Figure 2.14: Application of panel system as interior walls: (a) cellular concrete; (b)

gypsum board (Warszawski, 1999).

Figure 2.15: The use of wall panels in the building construction (Construction

Photos).

(a) (b)

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This system will require only large prefabricated sections to be transported or

handled at one time. This is an advantage due to high factory control and the number

of manhours required for the assembly on site can be reduced. The boxes can also be

stacked for high rise construction. In the case of high rise construction, the degree of

factory prefabrication is reduced for economic reasons of avoiding doubling of wall,

ceilings and floors. Depending on how it is used, the boxes can be made to be load

bearing or only support its own weight. The boxes can be produced in monolithic

form such as concrete boxes or be made in various sections joined together in the

factory. Figure 2.16 show arrangement of box units into position onsite.

Figure 2.16: Arrangement of box units into position onsite (Warszawski, 1999).

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The construction building that implement this system, will achieve the

ultimate objective of industrialisation - a maximum saving of human labour onsite.

Figure 2.17 shows the sequence of installation of box system onsite.

Figure 2.17: The sequence of installation of box system onsite (Construction Photos).

2.4 Classification for Types of IBS Used in Malaysia

The Industrialised Building Systems (IBS) is a construction process that

utilizes techniques, products, components, or building systems which involve

prefabricated components and on-site installation. According to CIDB-(1) (2003),

from the structural classification, there are five IBS main groups identified as being

used in this country, and these are:

(i) Precast concrete framing, panel and box systems

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(iii) Steel framing systemThis system covers steel trusses, columns beams and portal frame systems.

(iv) Prefabricated timber framing systemsThis system prefabricated timber trusses beams and columns.

(v) Blockwork systemsThis system includes interlocking concrete masonry units (CMU) and

lightweight concrete blocks.

2.5 The benefits of IBS

Commonly known and perceived by laymen as Dangerous, Difficult and

Dirty, the construction industry today has suffered spillover effect from the shortage

of foreign worker, unskilled workers at site and rise in both labour and material costs.

In order to revive and to further improve the image of the construction industry, IBS

can lead the way, given its advantages as an innovative construction method to the

construction industry.

The benefits of IBS can be presented as follows:

(i) The sa ing in man al labo r onsite ( p to 40 50% of the inp t in

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(iii) The repetitive use of system formwork made up of steel, alumunium, etcand scaffolding provides considerable cost savings (Binget al., 2001).

(iv) Reduction of elimination props due to the absence of conventional timberprops through the usage of pre-fabricated components (CIDB-(2), 2003).

(v) An Industrialised Building System allows the flexibility in architecturaldesign in order to minimize the monotony of repetitive facades (Warszawski,

1999).

(vi) This provides earlier occupation of the building, thus reducing interestpayment or capital outlays (Peng, 1986).

(vii) Large production output and standardisation of precast elements allow ahigh degree of labour specialisation with the production process. In such

working condition, workers are exposed to their work repetitiously with

higher productivity level (Warszawski, 1999).

(viii) The reduction of construction waste with the usage of the standardizedcomponents and less in-site works, thus providing a cleaner site due to lesser

construction waste (CIDB-(2), 2003).

(i ) Constr ction operation is not affected b ad erse eather condition beca se

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(xi) IBS provides safer construction sites due to the reduction of site workers,materials and construction waste (CIDB-(2), 2003).

2.6 Modular Coordination

Modular Coordination is a concept for coordinating dimension and space for

which buildings and components are dimensionalised and positioned in basic units or

modules. According to CIDB (2005) IBSDigest October December 2005 Issue,

MS 1064 introduces a certain geometric discipline using practical approaches which

relate to set-up coordination and measurement of components and spaces in the

building design.

The introduction of MC in the industry is to improve productivity and quality

in building construction as well as to act as a tool towards rationalisation and

industrialisation of the building industry. MC has been introduced in Malaysia since

1986, but has not been widely implemented in the building industry. The main

factors limiting the uses of MC in building industries is lack of knowledge on MC

concept and it requires precision dimensioning and proper planning.

The proper characteristics of MC are:

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(iii) Ergonomically designed to promote efficiency.

(iv) Internationally accepted to support international market.

MC may be applied to the design, manufacture and assembly of buildings, its

components and installations. It also affects the work of positioning and

dimensioning during construction. The concept of MC is based on:

(i) The used of modules (basic modules and multi-modules)

(ii) A reference system to define coordinating spaces and zones for buildingelements and for the components which form them.

(iii) Rules for locating building elements within the reference system.

(iv) Rules for sizing building components in order to determine their worksizes.

(v) Rules for defining preferred sizes for building components andcoordinating dimensions for building.

The principal objective of implementing MC is to improve productivity

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MC is an important factor in application of Industrialised Building System

IBS by way of standardization of components and dimensions such as reduce time of

production and installation of components, achieving repeatability and able to

construct building at lower cost.

2.7 J ust-In-Time (J IT) Management in the Precast Concrete Construction

Just-in-time (J IT) is defined as a philosophy of manufacturing based on

planned elimination of all waste and on continuous improvement of productivity

(Ahmad, 2005). It also has been described as an approach with the objective of

producing the right part in the right place at the right time (in other words, just in

time). Waste results from any activity that adds cost without adding value, such as

the unnecessary moving of materials, the accumulation of excess inventory, or the

use of faulty production methods that create products requiring subsequent rework

will be eliminated in J IT.

JIT (also known as lean production or stockless production) should improve

profits and return on investment by reducing inventory levels (increasing the

inventory turnover rate), reducing variability, improving product quality, reducing

production and delivery lead times, and reducing other costs (such as those

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in a continuous on-going process has helped to increase the efficiency of operational

and big scale project economy.

In the conventional construction sector, we can see that most of the works are

carried out at site. Therefore, construction process and labour work will be severely

affected by the weather. If the current situation persists, the construction work will

continue to depend on continuous labour force and the production rate will remain at

its lowest.

The implementation of J IT principle in the construction sector through the

introduction of precast elements is hoped to achieve such success rate that has been

long tasted in the manufacturing sector. In this situation, the work process will be

done in a controlled and closed environment. The site will only be the installation

place, whereas the components produced from the factory will be delivered to the

site and ready for installation.

The use of precast elements can help control the usage of formworks,

reinforcements and concrete in order to prevent wastage. Proper monitoring and

control and the quality assurance of raw materials and the steel moulds can ensure

the production of high quality products. In this case, prefabrication can meet the

demand of lean production. Figure 2.18 shows the JIT principle in the construction

ind str scenario

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Figure 2.18: The JIT principle in the construction industry scenario (Ahmad, 2005).

In the construction sector, we need a big space for the storage of materials at

site, and this will only reduce the capital budget. The need to prepare a large storage

area will not only waste money in allocating a large area for storage purposes, but if

the materials are not properly kept at site, it will affect the quality of the materials

greatly. Therefore, the implementation of JIT principle can save cost associated with

storage, since the materials will be delivered to the site in the right quantities and in a

controlled environment, to ensure that the quality of the components are guaranteed.

Since the materials will be delivered to the right place at the right time, this will also

reduce cost associated with storage of materials at site.

In this context, we can clearly see that the J IT principle has a good potential

in developing precast concrete components into eliminating the problem associated

with storage of materials at site, and also the heavy traffic problem at site. It is hoped

that the JIT principle can be fully implemented in the construction industry in our

Materials(not stored at site)

Delivered

In the right quantities In a controlled environment To the right place At the right time

J IT Concept

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2.8 Experiences Of Other Countries in IBS

IBS is gaining wide popularity among construction practitioners worldwide.

It can be seen that the international acceptance of IBS method into the construction

industries of respective countries clearly shows that such method is beneficial to the

construction sectors. Below are some reviews on the IBS acceptance in several

countries around the world.

2.8.1 The United States of America (U.S.A.)

IBS has begun as early as the 1930s as seen by the construction of

prefabricated steel houses by General Homes back then. However, due to price in

competitiveness, high capital investment and inconsistent local codes, the early

dream to popularise IBS as an innovative construction method began to fade off.

However, after the Second World War, the trend was brought up again due to the

rising need to resolve the critical shortage of houses.

According to Jacqueline (1999), a study was carried out by Portland Cement

Association (PCA) indicated that 70% of buyers in the US market select their dream

house on the basis of cost/value alone. In other words, the advantages in terms of

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In the United States of America (U.S.A.), timber framed is mostly used for

low rise housing, whereas concrete precast system is being used intensively

particularly in area that are vulnerable to environmental hazards as such hurricanes

and tornadoes. Concrete precast system is also applied in the construction of high

rise building in the USA due to its speed and ease in construction.

With the setting up of The Building America Industrialized Housing

Partnership (BAIHP), more researches and findings are carried out intensively to

formulate the best technology and construction methods to further promote IBS in

USA. Through such organization, IBS is gaining fast popularity in the USA market

in terms of high rise and low rise structures.

2.8.2 J apan

According to Nagahama (2000), the industrialisation of housing industry in

Japan started in 1960s and since then, the market share has changed dramatically

with the usage and application of IBS. As reported, from April 1999 - March 2000,

construction of prefabricated houses in Japan represented 20% of all houses built in

Japan during that period.

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T bl 22 P f b i dh i k h i J Fi l Y 1999(A il


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Table 2.2: Prefabricated housing market share in Japanese Fiscal Year 1999 (April

1999-March 2000) (Nagahama, 2000).

No Framing structure Prefabricated

Market Share, %

Growth Rate,

%

1 Steel framing 73 +3

2 Wood framing 18 +2

3 Concrete framing 9 -12

In spite of that, the Japan construction industry is still regarded as highly

integrated and automated production equipment and facilities to manufacture house

building components and offers home buyers both quality and aesthetic dream house.

2.8.3 Netherlands

In the past, the precast concrete in the Netherlands represents 10% of the total

housing market, although the conventional brick wall and masonry construction still

prevail in the market. Nevertheless, the industrialised housing is steadily increasing

its market share due to cost saving up to 30%. According to Jacqueline (1999), this

phenomenon is also substantiated by standardised components, flexible

manufacturing process and improved industrialised building technique.

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I N th l d i idi ith hi h ti iti i th b ildi i d t


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In Netherlands, coinciding with high activities in the building industry, new

ideas about efficiency were introduced in industrial production. There was a strong

belief that dimensional rules to manufacture modular parts of all kinds were the key

to a better building production at reduced costs. This was reflected in NEN 5700, the

first Dutch code on modular coordination, a two page document published in 1964,

in accordance with international ISO codes on the same subject. A direct relation was

suggested between dimensional co-ordination and an increased efficiency of the

building process and thus between standardization and industrialisation (NNI, 1978).

More codes were introduced thereafter, and this marks a milestone change in

the building industry in Netherlands. The building industry is changing from buildingon site using basic building materials to an assembly process: complete and complex

building parts are made in the factory and assembled on the site into a building.

Today, Netherlands is among one of the country that leads in the applicationof IBS components in the construction industry. Its strong concept on the benefits of

Open Building which aims to optimize the quality of the built environment, by

improving the relationship between the customer and the building industry has

attracted many countries worldwide to seek the expertise advice from the

Netherlands. The Open Building has indeed help to optimize building and

construction.

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then was less on aesthetics By the mid 70s thehousing situation had improved and


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then was less on aesthetics. By the mid 70s, the housing situation had improved and

more attention needed to be given to provide a total living environment for

residents. At this stage, the requirement for aesthetics and finishing quality began to

emerge. This trend carried on to the 80s and in the 90s, seeing new concepts like

mass customization emerging.

Based on the report by Tat and Hao (1999), during the period from

1973-1979, HDB of Singapore has again took a brave initiative to attempt IBS in

view of the need for accomplishing 100,000 dwelling units of housing units. As a

result of continuous effort, the HDB has made a remarkable achievement in the

adoption of IBS for the construction of the public housing program. These initiativesare the incorporation of modular co-ordination of its public housing designs, design

standardization and customization, prefabrication, and the mechanization of site

operations.

The setting up of HDB Prefabrication Technology Centre (PTC) in 1994

marks another milestone achievement in the application of IBS in Singapore. PTCs

main activities are to design, develop and produce prefabricated building products;

conduct research and development of advanced and innovative construction materials

and systems; manage and supply prefabricated building products; conduct training

and license its intellectual property rights.

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Precast refuse chute Precast ferrocement secondary roof panels

Precast volumetric household shelter Precast column

Precast facade Precast parapet

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285 Thailand


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2.8.5 Thailand

The application of IBS as an innovative construction method in Thailand is

gaining higher popularity as compared to the scenario of the construction industry in

Thailand way back in the 1970s. According to Buddhi (2004), in 2004, the

government of Thailand has a plan to build about 600,000 units within three years for

the low to medium income level citizens. Most of these family units are detached

houses.

Commissioned developers and designers have proposed different housing

systems. However, it is important to note that in terms of material, production,

construction, etc., the design must be suitable for large scale construction within a

limited time and cost. In July 2004, the National Housing Authority (NHA) of

Thailand has approved the usage of the Precast Large Panel Construction. This

marks another milestone for the construction industry in Thailand, where several

thousand PLP houses will be built within a period of several years.

PLP is another example of IBS components widely used in Thailand. PLP

structural system consists of normally reinforced precast concrete panels, precast

slabs and foundations. No beam and columns are used except at few locations. In

terms of the speed of construction, the total time required is significantly less than

thecon entional s stem According to B ddhi (2004) for a t pical 23 bedroomt o

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PLP Component Layout on Bed Casting of PLP components

Stacking of PLP components PLP components are lifted into position

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Other advantages of using PLP, which includes mass production, no removal


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g g , p ,

of formwork, less or comparable structural cost, quality control, usage of skilled

labour, low initial investment, modularization and automation and durability and

long term performance. Thailand is one of the countries actively introducing IBS

construction method into its construction industry. It is predicted that the

Government of Thailand will be able to achieve its target in providing 600,000 units

of housing units to its low and medium income group, thus providing the basic

necessities to its civilians, thanks to the application of IBS in its construction

industry.

2.8.6 Britain

The use of IBS in Britain became more evident in the mid 1900s after the

widespread destruction of housing units during the Second World War. According to

Jacqueline (1999), over 165,000 precast concrete dwellings had been built ranging

from small single bungalow to large high rise buildings by 1960.

In 1999, the precast concrete represents about 25% of the market for

cementitious products. This includes a wide range of products used in the

construction industry such as suspended floors, structural blocks, paving, cast stone

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2.8.7 Denmark


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According to Gibbons (1986), in Denmark, about 80% of the detached houses

produced since the mid-1960 were using IBS, most of it panelised system. The IBS

application in Denmark is aimed for domestic and export markets. For instance, its

international contractors such as Jespersen & Son and Larsen & Nielsen have

constructed many large-scale projects throughout the world, using prefabricated

concrete system produced from the local factories in their country.

In short, Denmark is not very lagging behind in terms of advancement in the

application of IBS in its construction industry. The construction companies from the

country are actively promoting IBS components from their country to the outside

world.

2.9 Malaysias own experience in IBS

The initiative to use and introduce IBS in Malaysia started off back in the

early sixties, when the Minister of Housing and Local Government visited some

European countries and evaluated their building systems performance. Din (1984)

reported that, it was then that the two pilot projects using IBS concept was carried

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With reference to the two pilot projects, it is found out that in terms of


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comparison of performance between IBS system and conventional system based on

cost, productivity and quality factor, the overall performance of IBS is more

competitive than the conventional method.

According to Badir et al. (2002), there are at least 21 suppliers and

manufacturers actively involved in promoting IBS in Malaysia. However, majority of

the IBS components are originated from the United States, Germany and Australia,

whereas Malaysia only contributed to a smaller portion of produced IBS components.

This shows that there are still ample of rooms for improvement and thus promoting

the application of IBS as an innovative construction method in our country is stillwidely open. Figure 2.21 shows the sources of IBS in Malaysia according to the

origin of countries.

UK

4%

Austria

8%

Australia

17%Germany

17%

US

25%

Othercountries

17%

Malaysia12%

Malaysia UK Austria

Australia Germany US

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be increased from 30% to 50% commencing 2005. Housing developers, who utilize


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IBS components exceeding 50%, will be given full exemption on levy imposed by

CIDB. This shows that the Government is trying to encourage the usage of IBS

components in the construction projects in our country.

According to CIDB-(2) (2003), only 15% of the local construction industry

has used IBS in Malaysia. Nevertheless, despite the high initial investment outlay,

some developers in Malaysia with sufficient economies of scale have taken proactive

steps and invested in IBS, mainly in formwork and structure. According to these

developers, IBS provided better and more consistent quality to their buildings, better

site management with less dependence on foreign workers.

According to MIGHT (2003) during a meeting on 24 January 2003 chaired

by Datuk Eddy Chen, REHDA Immediate Past Present, it is acknowledged that:

(i) IBS has been practised to a certain extent in Malaysia. PKNS, for instance,have built over 25,000 housing units using industrialized systems. JKR also

reported that they are using IBS for government quarters being constructed

all over Malaysia.

(ii) In JKRs case, they design the components (prefab slabs, beams, columns,infill panels) and based on the specifications, the market comes up with

44

(iv) That IBS should not only be related to high rise, but also low rise


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developments and also commercial buildings.

(v) Modular coordination (MC) must be emphasized. Knowledge of MC at alllevels (including local authorities personnel) must be enhanced. Everybody,

from owner to designer to authorities and contractors must familiarize

themselves with MC to prevent occurrence of huge mould modifications for

every new projects which is cost ineffective.

(vi) From consultants point of view currently they have to do 2 designs(conventional & industrialized) because specifying the designs as

industrialised will result in the client getting very small number of tenderersduring tendering process.

(vii) Agreed that there should be elements of incentivisation to IBS users developers, consultants etc. Incentives should also be given for partial IBS

usage.

(viii) Whether our human resource is ready to adopt IBS.

Although the CIDB has drawn up the IBS Road Map, Modular Design Guide,

catalogues of prefabricated components and many other guides with some reference

to implementation goals and timelines, achievements to date are unclear and of little

impact To ards this end it is necessar for CIDB to engage e perts ith

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The Government should set time-frame to gradually reduce intake of foreign


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labour into the construction industry. A monitoring mechanism will also need to be

set up to track progress of IBS industry development with objective key performance

indicators (KPIs). Vellu (2004) was quoted as saying; successful implementation of

the shift to IBS is expected to help the government in meeting its target of decreasing

foreign labour dependence by 85%.

For this system to be successfully utilized, both public and private sectors

would need to play their roles in educating the local construction industry. But aside

from voluntarily changing mindset, there must be some push factor to catalyze the

shift in mindset. Perhaps a good combination of carrot and stick, i.e. incentives andregulatory requirements for the introduction and adoption of IBS should be the next

concrete plan of action to be spearheaded by CIDB to further promote IBS in the

construction industry in our country.

2.10 Sequence of conventional construction method

According to Bannet and Grice (1985), for the conventional constructionapproach, it is based on the rigid separation of design and construction. The design

team prepares detailed drawings, specification and often Bill of Quantity. The tender

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ground. The building is actually made on the foundation. Usually a floor is laid on


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the foundation. Beams will then be constructed, followed by the construction of

columns and slabs. Where it is necessary, staircases will be constructed, before

eventually roof beams are constructed, followed closely by the construction of roof

trusses. When the roof is to be framed on the site, the top sill plate is nailed on top of

the wall sections. Cutting and nailing each piece of wood one at a time takes a lot of

time. Not only must each piece be cut but each piece must be carried up the ladder to

the right place.

Water proof roofing materials will be placed to ensure the roof is water proof

before roof tiles are placed in position. Brick walls will be constructed wherenecessary, with allocations for the placement of doors and window panels. Painting

and aesthetic decoration on walls and floor slabs will follow up and the end product

will be a complete on-site building.

Certainly, with so much on-going works happening on site, many skilled and

unskilled labourers are needed to carry out the works on site. Formworks have to be

constructed to specified dimensions and concrete casting will be done when all the

formworks and reinforcements have been properly laid on site. Weather is a common

factor that affects the working schedule on site, and often, material wastage is a

problem faced by contractors.

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2.11 Sequence of construction for IBS method


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IBS method is different from the conventional construction method. Known

for its benefits in terms of shorter construction time, saving in labour, material saving,

better quality control, immunity to weather changes and the cost factor, IBS method

illustrates a different approach to the construction method commonly used. It offers

an alternative to the existing conventional building system.

Among one of the most important characteristics of IBS method is IBS

components are prefabricated offsite. According to Chew and Michael (1986),

prefabrication system of construction means breaking a whole housing unit into

different components such as the floors, walls, columns, beams, roofs, etc. and

having these components separately prefabricated or manufactured in modules or

standard dimensions in a factory. Figure 2.22 show sequence of activities of IBS

construction method.

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Design Production line

Form a final unit Assemble and erection Delivery to site

Figure 2.22: Sequence of activities of IBS construction method (Construction

Photos).

IBS method emphasizes on prefabrication concept. Firstly, the design stage is

carried out where the IBS components are designed according to specifications. Then,

the components are prefabricated at factory, where components of IBS are

manufactured according to specified dimensions and specifications.

Quality-controlled and highly aesthetic end products through the processes of

controlled pre-fabrication and simplified installations has maintained and ensured the

quality of work in the construction industry.

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IBS method offers a new concept in terms of speed of construction, and it


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clearly shows many other benefits as compared to the conventional construction

method. According to Chew and Michael(1986), IBS also consists of 2 types of

prefabricated systems in the market, namely; fully prefabricated system and partially

prefabricated system.

Fully prefabricated system is referring to the components produced in the

factory and later transported to the site for erection. Fully prefabricated system

consists of 3 categories, namely; panel system, frame system and box system. Further

description and explanation of the above-mentioned systems has been clarified in the

sub-section before.

Partially prefabricated system is a type of system in construction where

certain elements that can be standardized are prefabricated in the factory, whereas

other components are cast in-situ. In this construction method, certain elements as

such wall panels, slab panels and staircase are considered as precast components,

while the columns, beams and the foundations are usually cast in-situ due to ease and

speed of construction. According to Chew and Michael (1986), this system usually

give more rigid construction and better water tightness characteristic, which are

normally a big problem with the usage of panel system and frame system.

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workload on the production process in the very short run. Operations control entails

it i j b d d h diti d d/


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monitoring job-order progress, and where necessary, expediting orders and/or

adjusting system capacity to make sure that the MPS is met. Scheduling should be

reviewed and agreed upon by the general contractor and/or the construction manager.

In designing a scheduling and control system for IBS formation scheduling,

provision must be made for efficient performance of the following functions:

(i) Allocating orders, equipment, and personnel to work centres or otherspecified locations. Essentially, this is short-run capacity planning at site.

(ii) Determining the sequence of order performance; that is establishing jobpriorities at site.

(iii) Initiating performance of the scheduled work. This is commonly termed thedispatching of orders for IBS formation at site.

(iv) Shop-floor control (or production activity control), which involves:(a) Reviewing the status and controlling the progress of orders as they are

being worked on.

(b)

Expediting late and critical orders.

(v) Revising the schedule to reflect recent changes in order status.

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controlled quality and great precision. Once the precast components are produced

and pre fabricatedat fabrication plant theIBS components will later be transported


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and pre-fabricated at fabrication plant, the IBS components will later be transported

to the site for assembly and erection purposes. This is where the scheduling of IBS

components is very vital as to ensure proper coordination of work and good timing

when assembling process is carried out at the site.

At the start of the day, the job dispatcher, or normally a site engineer assigned

to the scheduling task will select and sequence the available jobs to be run at

individual workstations at site. The engineers decisions would be based on the

operations and routing requirements of each job, status of existing jobs on the

machines, the queue of work before each machine, job priories, material availability,

anticipated job orders to be released later in the day, and worker and machine

capabilities.

To help organize the schedule, the engineer would draw on shop-floor

information from the previous day and external information provided by the

production control, process engineering, and so on. The engineer would also confer

with the foreman or supervisor of the department about the feasibility of the schedule,

especially with respect to workforce considerations and identifying potential

bottlenecks. Clear and visual schedule boards are efficient ways to communicate the

priority and status of work.

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An experienced installer will prove helpful in these situations, especially if it

is necessary to alter the order Prior to delivering precast product and having


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is necessary to alter the order. Prior to delivering precast product and having

expensive cranes, other equipment, and installation crews show up at the site, it is

essential that the site be properly prepared. The more site preparation you do, the

smoother, and it is hoped, and less costly the installation will go.

2.12.1 Scheduling Methods

In the scheduling phase of IBS components at the site, the cross-functional

team specifies the project plan in more detail. This phase begins with the

construction of a detailed list of project activities, called the work-breakdown

structure. A detailed time schedule for each activity in the work-breakdown structure

is then established, using several methods and software. When the time schedule is

completed, a time-phased budget, which is keyed to the start and completion times of

each of the project activities, can be developed. Finally, the project personnel can be

assigned to individual project activities.

Several types of scheduling methods are in use. These may be generallyclassified as Gantt Chart or Network methods. The Gantt Chart methods utilize a bar

or milestone chart. The network methods use a graph or network to show precedence

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There are many scheduling software available in the current market

nowadays which makes scheduling an easier and simpler task This includes


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nowadays, which makes scheduling an easier and simpler task. This includes

Primavera P3, Microsoft Project, Artimes, Pro-Plan, SureTrack Project Manager,

Milestone and so on. All these scheduling software plays a vital role in IBS

formation scheduling which makes job coordination and planning to be accurate and

speed up construction time.

2.12.1.1Microsoft Project as a Scheduling Software

In IBS scheduling, Microsoft Project is a software commonly used for

scheduling of project resources. It enables the control monitoring for the progress of

project activities and revises the plan accordingly. It has a combine element of Gantt

Chart and Network methods in order to enable scheduling to be done precisely.

The advantages of Microsoft Project as scheduling software in IBS

scheduling includes its ability to begin inputting activities data using Gantt Chart,

enables user to modify its planning sequences in case of any changes to the activities

and durations, and lastly, provides easy understanding to end user. Microsoft Projectalso enables planning and monitoring of activities on site to be much easier and more

efficient.

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2.13 IBS Scheduling for Public Buildings


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This study has been conducted to emphasize on analysing the best scheduling

ways for IBS components involving the construction of public buildings. Public

buildings here mainly referred to schools, universities, community halls and so on.

The reason why public buildings such as schools has been chosen as the subject of

this study, mainly is because, conventional construction method for schools would

normally take approximately 3 years or perhaps even longer, just to complete the

construction of the schools!

To add matters worst still, the newly-constructed school buildings often face

shortages of classrooms and facilities, as a result of ignorant contractors and

developers who wish to earn more, resulting in inadequate facilities being

constructed. Furthermore, the architectural concept of schools in Malaysia has not

changed for such a long time, often resulting in poor images in terms of aesthetic

value.

To date, our country still faces the shortages of school buildings to cater for

the increasing number of students. With the current speed of conventional

construction method involving construction of schools throughout the country, it

occurs that there is an urgent need to solve this problem as soon as possible. The

reason is that nless some methods are carried o t to impro e the c rrent

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Therefore, IBS construction method has been identified as an alternative to

solvethisproblem.Therefore, thefocusof this studywill mainlybetargetingon IBS


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solve this problem. Therefore, the focus of this study will mainly be targeting on IBS

application mainly on public buildings, especially in terms of schools in our country.

Proper scheduling techniques should be implemented especially on IBS components

at the site to ensure proper coordination of work and speedy construction. Efficient

scheduling of IBS components at site is vital in ensuring the smooth flow of

construction sequences at site.

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CHAPTER II I

RESEARCH METHODOLOGY

3.1 Introduction

The research methodology in this chapter serves as a guide to the author in

achieving the objectives and scopes of the study. This chapter shall further discuss in

detail the research procedures, from how the data is collected till how it is processed

and analysed to achieve the objectives and scopes of the study.

3.2 First stage: Identification of research topic and scope of study

At this stage, it involves the identification and further understanding of the

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Flow chart of the research methodology


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Identification of the research topic and scopes of

Scope of study

Data Collection:

9 Construction sequence to follow conventional type ofconstruction.

9 Time frame for each IBS activities.9 Details of the proposed lifting system at site.

Results and analysis:

(i) Compare the scheduling process of both conventional andproposed IBS method.

(ii)Analyse the critical outputs in managing the scheduling ofproject.

(iii)Comparative check of proposed IBS school design with the

Uniform Building By-Law 1984.

First

stage

Second

stage

Third

stage

Literature reviewObjectives of study

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3.3 Second stage: Data collection


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Data collection is an essential aspect of the research methodology, where it

involves ways to collect data and information to assist in the data analysis and

interpretation. The data collection also emphasizes on the construction sequence of

IBS components to follow conventional construction method. This means that, the

sequence of construction and erection of IBS components at site shall follow the

sequence of conventional construction method.

Besides, data collection also involves the determination of time frame of

each activity in the proposed IBS method. For this purpose, it involves site studies at

several construction sites implementing IBS method in the construction process.

Interviews have also been conducted with several precasters, main contractors and

precast specialist sub-contractors in obtaining the data for the time frame of each

activity for the IBS method.

Other data collection also involves the details of the proposed lifting system

at site, with the capacity of cranes required, its working radius and its working

productivity while handling the installation of precast components at site. Site studies

for the lifting system have also been carried out at several sites utilizing IBS method

in its construction project. Further study which includes interview session with the

s pplier of the crane eq ipments for major constr ction projects in the co ntr has

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productivity of different lifting systems and whether the productivity will be severely

affected if the lifting systems are not available or its usage are limited due to


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machinery fault or unavailability of cranes at site.

A conceptual school building built using IBS components is modelled. At this

stage, the conceptual school is based on the criteria where the school building is

required to accommodate 1500 students for morning session only. Here, morning

session is referred to the period of studies from 8 am till 3 pm. This conceptual

school is based on the requirement where the students mainly comes from different

streams, such as technical, science, accountancy, agricultural science and art stream.

The school building is required to have full facilities, which includes

sufficient classroom where each classroom will only accommodate 30 students,

instead of the usual 50 to 60 students per classroom currently. This will enable

students to study in a more conducive learning environment, and hopefully gone

were the days where students were cramped inside a small classroom for each lesson.

Other amenities such assurau for Muslim prayers, locker cabinets, computer rooms,

meeting rooms for every curriculum activities, laboratories, libraries, toilets and so

on will be located strategically in the compound of the proposed conceptual school.

This conceptual school also emphasizes on having 1 classroom with two

attachedteachers room Inother ords therearenomorecentralisedteachersroom

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Therefore, this study is conducted in order to achieve the aim of

constructing such conceptual school in our country, replacing the old conventional


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schools that we have currently. In order to achieve such target and objective, it is

important to consider the construction process of the school. Currently, it is

saddening to see that a typical school in Malaysia will take approximately more than

2 years or perhaps longer, just to get it constructed. When the school is open to

students, problems such as insufficient classrooms and other facilities will greet thearrival of students, much to the displeasure of parents. It is hoped that the conceptual

school proposed in this study will soon overcome the problems arising, as mentioned

above.

In order to construct the proposed conceptual school, IBS construction

method has been proposed, where IBS components will be used in the construction

of the school. IBS construction method has been known for its speed of construction

benefit, high quality end products, and most importantly, it can help to solve the

shortages crisis of schools in our country in a faster and efficient way. This can

further solve the problem haunting the construction of schools currently, which take

years to complete the construction of the entire school buildings.

IBS components such as precast columns and beams are proposed in the

construction of the conceptual school. The use of precast columns and beams will

enhance the speed of completion of the entire school project. It is believed that with

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process. In order to prepare a good scheduling for IBS components used in the

construction of the conceptual school, several factors have to be taken into


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considerations. Such factors include production of IBS components at factory,

transportation to site location, labour supply, may it be in terms of skilled and

unskilled labourers, availability of components and lastly the erection and assembly

of IBS components at site.

In this context of study, the focus of study is particularly to emphasize on

the scheduling of IBS components at site. In other words, this study is mainly

focussed on assembly time of the conceptual school using IBS components.

Therefore, other factors such as production of IBS components at factory,

transportation to site location, labour supply and availability of IBS components has

to be maintained constant.

The reason being is that, when all other factors are maintained constant,

therefore, there should not be any problem occurring from the design stage till the

transportation stage. It will be presumed that all of these factors have been well taken

care of till the IBS components have arrived at the site. The only main concern would

be when the IBS components have arrived at the site, the scheduling of IBS

formation and erection has to be focussed in order to achieve effective work schedule

and speed of construction.

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Further study will also be conducted to analyse how long does it takes to

assemble the components at the site to produce the entire conceptual building of the


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proposed school. It is important also to determine whether it takes the same speed

and time to install the IBS components compared to conventional Cast-In-Situ

method. Scheduling of IBS components at site can also help to further determine the

work duration of the entire project implementing IBS components, as compared to

conventional methods.

3.4 Third stage: Results and analysis

At this stage, the assembly and erection of the proposed conceptual school

has been modelled using computer software and will be analysed. More emphasize is

on how the scheduling on assembly time is carried out efficiently at a site using IBS

components for the proposed conceptual school. Therefore, a comparison betweenthe work breakdown structure (WBS) between a typical school construction using

conventional construction method and the other using IBS components for the

proposed conceptual school will be further analysed. Microsoft Project will be the

scheduling software to be used for scheduling purposes, and the results generated by

the software will be carefully analysed at this stage.

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3.5 Fourth stage: Make conclusion


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At this final stage, a conclusion will be drawn out based on the results of the

analysis obtained. Final checking will be carried out at this stage to improve the

quality of the research study and also to improve the loop holes in the study

conducted.

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