Short Case Study On HKL SCACC

Short case study on Hospital Kuala Lumpur Specialist Complex & Ambulatory Care Centre (HKL SCACC)- The first IBS70 government hospital project in Malaysia

Table Of Contents 1 2 3 4 IBS construction technology in action Summing up the IBS score IBS in construction procurement & costing IBS in contract management considerations

1. IBS construction technology in action Keywords About IBS Standardization / Penyeragaman

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Component Size Industry Standard (Specification) Component Code Modular Basic Module Modular Coordination / Dimension Coordination Basic Unit Malaysian Standard MS 1064 Off -Site Assembly Prefabrication Precast IBS Scoring On-Site Installation Delivery & Hoisting Specialized Workers Higher Cost

Implementation Of IBS System For Government Projects Surat Pekeliling Perbendaharaan - 31 Oktober 2008 Pengunaan Sistem Terbuka Melalui Modular Kordinasi MS 1064 Keperluan 70% Kandungan Komponen IBS dalam Projek Kerajaan

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Unit Penyelarasan Pelaksanaan, Jabatan Perdana Menteri Sebagai Permantau Sekretariat IBS Kebangsaan Sebagai Penyelaras Pusat IBS CIDB Sebagai Pusat Rujukan Setempat Project Team Owner = Ministry of Health, Malaysia End User = General Hospital Kuala Lumpur Client & Project Manager = Ministry of Works, Malaysia Design & Build Contractor = Setia Precast Sdn Bhd Architect, Medical Planner & ID Designer Consultant = i-TAAC Architect Civil & Structure Consultant = Pakatan Runding Yusoff Sdn. Bhd. Mechanical & Electrical Consultant = KTA Tenaga Sdn. Bhd Perunding Ukur Bahan = Baharuddin Ali & Low Sdn. Bhd. Perunding Rekabentuk Lanskap = Urban Design Group Perunding Peralatan Medikal = Advance Pact Sdn. Bhd.

Contract Particulars Date of Possession = 15th June 2009 Date of Completion = 14th December 2011 Contract Period = 30 months Maintenance Period = 24 Months after Completion Date Contract Sum = RM 234,000,000.00

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Site Location

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Site Plan

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Project Brief
Items 1 2 3 4 Location All Departments OT 2 to 4 floor
nd th

Descriptions CE Rooms Operating Theater Carparks

Quantity 184 9+1 300 bays

Remarks

The Specialist Clinics and Other Non-clinical Departments Level 0 (Ground Floor) 01) Orthopaedics 02) Medical Imaging 03) Clinical Laboratory 04) Outpatient Pharmacy 1 Level 1 05) General Medicine Specialist Clinic 06) General Surgery Specialist Clinic 07) Dental Specialist Clinic 08) Social Services Unit Level 2 09) Haemodialysis Clinic 10) Nephrology Specialist Clinic 11) Urology Specialist Clininc Level 3 12) Psychiatric Specialist Clinic Level 4 13) Neurosurgery Specialist Clinic 14) Neurology Specialist Clinic Level 5 15) ENT Specialist Clininc 16) Opthalmology Specialist Clinic 17) Oncology Specialist Clinic & Day Care 18) Plastic Surgery Specialist Clinic 19) Dermatology Specialist Clinic

4 (cont.)

Level 6 20) IT Area 21) Medical Records 22) Specialist Office Complex

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Items

Location 23) Skill Lab 24) Anaesthetic & Pain Specialist Clinic 25) Day Care ( Endoscopy Suite ) Level 7

Descriptions

Quantity

Remarks

26) Respiratory & Haemodynamic Equipment Unit 27) Theatre Sterile Supplies Department (TSSD) 28) Day Care 29) Cytotoxic Drug Unit 30) Operation Theatre 5 DIAGNOSTIC IMAGING EQUIPMENT X-Ray, General, c/w Chest Stand X-ray Fluoro w 90/15 w ERCP Table X-ray Fluoro w 90/15 endo-uro table 38cm II Extracorporeal Shock Wave Litho. (ESWL) Digital Orthopantomography (OPG) CR System complete w Laser Printer CT Scan, 16 slices X-Ray C-Arm, 9" II with 2 Mon. 6 OPERATING THEATRE (LIGHTS& TABLES) Light, Op, Ceiling, Main 110K + Sat. 80K Lux Light, Exam, Ceiling, 30k lux Table, Operating, General, Elec. cw Accs. Table, Operating, Ortho, Elec. cw Accs. Table, Operating, ENT, Elec. cw Accs. Table, Operating, Urology, Elec. cw Accs. Table, Operating, Opth, Elec. c/w Accs. 7 CSSD Autoclave, Pass through, 30ft Cabinet, Drying, Pass through Sterilizing Basket ss 575x280x130mm Sterilizing Basket ss 575x280x260mm Shelf Wire CSSD ss 900(36")X1200(48")X63"(WLH)mm - Group 1 Distribution/Collection Trolley, ss 1195x695x975mm Loading/Unloading Trolley, for Washer Disinfector/Dryer 2 1 70 70 42 10 6 8 41 3 2 1 1 1 4 1 1 1 1 2 1 2

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Items

Location

Descriptions

Quantity 1 4 1 1 1 1 3 12 1 3 2 4 6 3 2 4 2

Remarks

Hatch, Pass Through ~ open: 600X 600 mm Loading/Unloading Trolley for Steam Sterillizer Reverse Osmosis Water System, Barrier Panelling, Sterillization, ss Barrier Panelling, Cleaning & Disinfection, ss Steriliser, Hydrogen Peroxide, ~ 100L Washer / Disinfector, Pass Through Endoscope Washer Disinfector Endoscope Sterilizer -Group 1 Washer/Sanitiser, Bedpan Stainless Steel Gauze Cutting Table Stainless Steel Mobile Work Table Stainless Steel Packing Table Stainless Steel Paper Trolley Workstation for Heat Sealer, ss Worktable s/s Mobile, 1080x500x800mm Stainless Steel Linen Inspection Table 8 DENTAL Suction Machine (12 Chairs) Air Compressor w Dryer (12 Chairs) Chair Dental Treatment Unit (Officer) Chair Dental Treatment Unit (Specialist) Dental Technologist Workstation Set 9 LAB Fume cupboard 4 ft Fume cupboard 6 ft Cabinet, Cytotoxic Drug w UV Lamp 10 Others RO System, w Piping, UV Light & Tank

2 2 5 4 8

1 1 1

IBS Component In Use (Structural & Architectural) Precast Hollow Core Slab Prefab Steel Roof Sr Yeap Soon Kiat Dec 2010 Kuala Lumpur yskiat@yahoo.com Page | 18

Precast Wall Precast Beams Precast Cornice & Moulding Precast Staircase Aluminium System Formwork

Speed Of Progress Of Work Estimated at 1 month 1 floor for structure framing Estimated at 1 month 1 floor for precision blockwork

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2. Summing Up The IBS Score Began In 1 Februari 2005 Perintah Lembaga Pembangunan Industri Pembinaan Malaysia (Pengecualian Levi 2005) yang mula berkuatkuasa pada 1 Februari 2005 Mechanism for exemption on CIDB levy for project use IBS (landed and high rise residential project only) IBS Score Percentage Distribution Maximum IBS Score for a building is 100% Structural system (max 50%) -contributes most wet trade; 75% labour

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Wall system (max 30%) - widely available in the market Others Simplified Saving Construction Solution (max 20%) - standard components MS1064; repetition; 3D components; etc Structural system Points are awarded based structural system used Allocation based on % floor area that utilises the structural system Sub-structure works (elements) are not taken into account in the calculation e.g. Piling, ground beam, ground slab, underground car park etc) The construction area includes car porch but excluding driveway, apron and landscaped areas For structural system using Load Bearing wall, whether precast or in-situ the factor can be determined from the table by treating the wall as wide column The factor for tunnel formwork system is 0.6 This is for structural without floor. For other structural systems not mentioned in the table please refer to CIDB for the factor IBS Factor For Structural Systems In-situ SYSTEM FLOOR Precast concrete concrete on slab(1) permanent COLUMN metal /BEAM formwork (5) (6) Precast column CONCRETE 1.0 0.9 and beams Precast column and in-situ beams using 0.9 0.8 reusable(3) system

In-situ In-situ Steel concrete concrete flooring system using using reusable(3) timber(4) system formwork formwork 0.7 0.6 1.0

Timber frame flooring system

1.0

0.6

0.5

0.9

0.9

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SYSTEM

FLOOR Precast In-situ In-situ In-situ Steel concrete concrete on concrete concrete flooring slab(1) permanent using using system COLUMN metal reusable(3) timber(4) /BEAM formwork system formwork (5) (6) formwork formwork Precast column and in-situ beams using timber(4) formwork Precast beams and in-situ columns with reusable(3) system formwork Precast beams and in-situ columns using timber(4) formwork In-situ column and beams using reusable system(3) formwork In-situ column and beams using timber(4) formwork Steel columns and beams Timber frame system Prefab timber roof truss Prefab metal

Timber frame flooring system

0.8

0.7

0.5

0.4

0.8

0.8

0.9

0.8

0.6

0.5

0.9

0.9

0.8

0.7

0.5

0.4

0.8

0.8

0.7

0.6

0.5

0.3

0.7

0.7

0.6

0.5

0.3

0.0

0.6

0.6

STEEL TIMBER ROOF SYSTEM

1.0

0.9

0.7 1.0 1.0 1.0

0.6

1.0

1.0

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SYSTEM

FLOOR Precast In-situ In-situ In-situ Steel concrete concrete on concrete concrete flooring slab(1) permanent using using system COLUMN metal reusable(3) timber(4) /BEAM formwork system formwork (5) (6) formwork roof truss Timber(4) roof 0.0 trusses

Timber frame flooring system

Wall System Points are awarded based wall system used Allocation based on % length of the wall system used External basement wall for earth retaining purposes and toilet cubicle partition walls are excluded from the calculation For cavity wall, consider the two separate skins as a wall Parapet and corridor must be counted in the calculation

IBS Factor For Wall Systems NO 1 2 3 4 5 WALL SYSTEM (7) Precast Concrete Panel (1) Metal Cladding Prefabricated Timber panel Full height Glass panel (2) Dry Wall system (3) IBS FACTOR 1.0 1.0 1.0 1.0 1.0

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NO 6 7 8 9

WALL SYSTEM (7) In-situ concrete with reusable(4) system formwork In situ concrete with timber(5) formwork Precision blockworks(6) Common Brickwall

IBS FACTOR 0.5 0.0 0.5 0.0

Other Simplifying Features Use of standardised components; MS1064 (Beams, columns, walls, slab, windows, door)

Use of prefab components; toilets, staircase etc Repeating features grids, floor ht, etc Vertical repetitions, horizontal repetition Labour saving techniques, spray plaster

IBS Factor For Other Simplified Construction Solutions No DESCRIPTION UNIT 1 UTILISATION OF STANDARDISED COMPONENTS BASED ON MS 1064 i) Beams(1) ii) Columns(1) iii) Walls(1) iv) Slabs(1) v) Doors(2)

IBS SCORE PERCENTAGE OF USAGE 50% x <75%, 75% x 100%

Nos Nos m m2 Nos

1 1 0.5 0.5 1

2 2 1 1 2

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No

DESCRIPTION UNIT vi) Windows(3) Nos

IBS SCORE PERCENTAGE OF USAGE 50% x <75%, 75% x 100% 1 2

2 REPETITION OF STRUCTURAL LAYOUT a) For building more than 2 storeys i) Repetition of floor to floor height ii) Vertical repetition of structural floor layout b) For building 1 or 2 storeys Horizontal repetition of structural floor layout OTHER PREFABRICATED COMPONENTS AND LABOUR SAVING SOLUTIONS i) Prefab Toilet Units ii) Prefab Staircases iii) Prefab Lift-Shafts iv) Spray plaster(4) v) Other Labour Saving Product / Solution(5) m2 2 5

storey m2

1 1

2 3

Nos Nos Nos m2 Nos or m2

0.5 0.5 0.5 0.5 0.5

1 1 1 1 1

3. IBS in Construction Procurement & Costing 2 Steps In Estimating IBS Construction Cost Identify the key cost elements of construction elements with IBS systems Pre-cast Concrete Framing Pre-cast Concrete Panel Pre-cast Concrete Floor Steel Formwork Systems

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Structural Steel Blockwork Approaches for establishing the IBS project cost Elemental Measurement Detail Measurement Production Cost Estimation Precast Hollow Core Slab Costing Example
PRECAST CONCRETE The design, supply, delivery and installation of precast component:Hollow Core Slabs Supply and delivery of Precast Prestressed Hollow Core Slabs.(HCS: WV6-205mm thick) Precast prestressed hollow core slab; 265mm thick Installation & grouting of hollow core slabs & planks in thicknes:- 300mm & below (labour only not inclusive cranage) Grouting works to precast system which is HCS/ plank shearkey joint to: (E.mix) WV6-205 (labour & material) Associated Concrete G30 to topping. Associated concrete Grade 40 to beam infill. Associated rebar to topping Assoicated rebar to shearkey. Associated work of RD6 mesh to topping measure nett, allow lap in rate. Associated formwork to underside of hcs at perimeter beam end Associated formwork to edge of topping

M2 M2

24,310 19,101

M2

24,310

M M3 M3 Kg Kg M2 M M

20,258 2,301 68 18,496 5,651 27,128 1,786 1,880

Precast Beam Costing Example

PC Beams machinery Plant Construction Steel Work Steel Mould Runnin cost Dismantle LS LS LS LS LS LS -------

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Material Cost Labour Cost Double Stock & Damanged Panel Transportation Installation of precast beams grouting works:Steel Plate Ditto Transport Ditto Plumb Prop. Wire Rope Small Tools Labour Cost Beam Erection/ Joint Labour Cost HCS Erection Grouting Cost HCS Shear Key Joint Labour cost Erection/Joint Earthwork for passage C/Run for Crane Passage Ditto - Maintenance

LS LS LS LS and LS LS No Set LS No M2 M No LS M3 Mth

-----

--2 2 -1,022 31,093 25,910 96 -180 9

4. IBS in contract management considerations Ideas To Increase IBS Score By increase usage of Precast Hollow Core Slab Precast Half Slab Precast Waffle Slab Precast Plank Prefab Steel Roof Steel Structure Precast Wall Precast Beams Precast Columns Precast Cornice & Moulding Precast Balcony Precast Staircase Offsite Barbending 3D toilet module (POD) System Formwork (metal / aluminium / plastic) Construction Considerations Heavy lifting crainage / tower crain

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More full time crainage Different lifting contraption Walky-talky Sub-contracting Limited IBS system / brands Lack of connection / integration of IBS components Required a lot of floor to floor & services by services planning & coordination Allow for starter bars or connectors Cost Considerations Savings on formwork Savings on timber scaffolding Savings on construction period Lower labor content Less wastage Higher cost of IBS High initial / setup cost of IBS Less competitive tender price Need high tech contractors / sub-contractors Alteration / Renovation Consideration Difficult to accommodate, needs to be pre-planned upfront Requires hacking Structural elements cannot be hacked Sr Yeap Soon Kiat Dec 2010 Kuala Lumpur yskiat@yahoo.com Page | 18