EAA484/2

BUILDING
CONSTRUCTION AND
TECHNOLOGY
Dr. Sharifah Akmam Syed Zakaria
School of Civil Engineering
Email: akmam@usm.my
 TOPICS:
1. Industrialized Building System
2. Green Building Technology
1. INDUSTRIALIZED BUILDING SYSTEM

Course Outcome 1:
Able to apply knowledge in construction technology in
the construction of building and infrastructure.

Course Outcome 2:
Able to suggest appropriate construction materials and
techniques to suit various construction requirements.
 IBS - Topic Objectives: We l e a d

Understanding of:
• The concept of IBS construction project.
• IBS components.
• The category of IBS projects and installation
process .
• The handling of clients needs in IBS project
implementation.
 IBS - Topic Objectives: We l e a d

Understanding of:
• The concept of IBS construction
project.
• IBS components.
• The category of IBS projects and installation
process .
• The handling of clients needs in IBS project
implementation.
 IBS Definition We l e a d

• In Malaysia, the Construction Industry

Development Berhad (CIDB) defines IBS as:

“a technique of construction whereby building

components are manufactured at factories or off
site, transported and then assembled into a
structure with minimum work.”
 IBS Explanation We l e a d

• Worldwide, IBS is also known as Pre-

fabricated/Pre-fab Construction, Modern
Method of Construction (MMC) and Off-site
Construction.
• CIDB Malaysia, through IBS Centre is
promoting the usage of IBS to increase
productivity and quality at construction
sites through various promotion programmes,
training and incentives.
 We l e a d

• Industrialisation process is an investment in

equipment, facilities and technology with the
objective of maximising production output,
minimising labour resource and improving
quality…
• while a building system is defined as a set of
interconnected element that joint together to
enable the designated performance of a
building.
 We l e a d

• The industrialised building system (IBS) can be

defined in which all building such as wall, slab,
beam, column and staircase are mass produced
either in factory or at site factory under strict
quality control and minimal wet site activities.
• IBS in construction industry includes the
industrialised process which the components are
conceived, planned, fabricated, transported and
erected on site.
 We l e a d

• IBS is a continuum beginning from utilizing

craftsman 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.
 Fast construction using IBS Concrete Panels.
Practical Example | Industrialized
Stronger structure due to monolithic Building
construction System
method.
Making it earthquake resistance and storm resistance.
Fast and cheaper way to build house.
 The five characteristics of IBS: We l e a d

1. Industrial production of components though

prefabrication; or highly mechanised in-situ
processes i.e. slip-forms, post-tensioning,
tunnel shutters.
2. Reduced labour during prefabrication of
components and site works.
3. Modern design and manufacturing methods
i.e. involvement of Computer Aided Design
(CAD) and Computer Aided Manufacturing
(CAM).
 We l e a d

4. Systematic Quality Control i.e. ISO 9000

principles.
5. Open Building Concept i.e. permitting hybrid
applications, adaptable to standardisation
and Modular Coordination (MC).

Systems to be accepted as part of IBS need to

possess all of the above, as all of the five
characteristics are equally important to ensure
the achievement of the claimed benefits.
 We l e a d

• The benefits of IBS in construction has been

well-documented, but despite high-profile
projects such as the Petronas Twin Towers and
Putrajaya, both of which include pre-
fabricated components, uptake of IBS
solutions in the Malaysian construction
industry has been slower than expected.
 History of IBS in Malaysia
We l e a d

• Malaysia
• 1964: Initial study in Europe
• 1966: First Project– Flat
Pekeliling
i. 7 blok 17 tingkat, -
ii. 3000 unit kos rendah
iii. 40 kedai
• JV Gammon (Contractor)
• Completed in 27 months

Flat Pekeliling KL
 We l e a d

• 1969: 6 blocks of 17 stories dan 3 blocks of 18

stories at Jalan Rifle Range, Pulau Pinang.
• Constructed by Hochtief dan Chee Seng; Estoit
system from France.

- Taman Tun Sardon,

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

Rifle Range Penang

 We l e a d

• Housing projects since 1970-1980s

• Hybrid application since 1990s
i. KLIA,
ii. Stadium Bukit Jalil,
iii. Putrajaya,
iv. KL Sentral, Menara KL,
v. KLCC,
vi. LRT dll.
 IBS - Topic Objectives: We l e a d

Understanding of:
• The concept of IBS construction project.
• IBS components.
• The category of IBS projects and installation
process.
• The handling of clients needs in IBS project
implementation.
 We l e a d

• In Malaysia, Construction Industry Development Board

(CIDB) has classified the IBS system into 5 categories as
follows:
1) Pre-cast Concrete Framing, Panel and Box Systems –
pre-cast columns, beams, slabs, balconies, staircases,
toilets etc.
2) Formwork Systems – tunnel forms, EPS-based forms,
beams and columns moulding forms, permanent steel
formworks etc.
3) Steel Framing Systems – steel beams and columns,
portal frames, roof trusses. etc.
4) Prefabricated Timber Framing Systems – timber
frames, roof trusses etc.
5) Block Work Systems – interlocking concrete masonry
units (CMU), lightweight concrete blocks, etc.
We l e a d
We l e a d
 TYPE 1 We l e a d

• Type 1: Pre-cast Concrete Framing, Panel and

Box Systems
• The most common group of IBS products is
the pre-cast concrete elements.
• Including pre-cast concrete columns, beams,
slabs, walls, “3-D” components (e.g.
balconies, staircases, toilets, lift chambers,
refuse chambers), lightweight pre-cast
concrete.
• …as well as permanent concrete formworks.
 We l e a d

Tunnel forms, beams

and column moulding
forms, permanent steel

2 formworks (metal decks),

etc.
 We l e a d

PC columns, beams,

2 slabs, 3D-components
(balconies, staircases,
toilets, lift chambers, box
girders, etc)
 We l e a d

• Type 1: Pre-cast Concrete Framing, Panel

and Box Systems : Plant-Cast Precast
Concrete
• Concrete elements, cast and cured in a
manufacturing plant, then transported to the
construction site.
• Plant casting allows increased efficiency and
higher quality control.
• Durable, permanent steel forms are reused
many times, reducing formwork costs
compared to site cast concrete.
 We l e a d

• Use of Type 1, high early strength cement and

steam curing allow concrete members to be
cast and cured in as little as 24 hours.
• Controlled casting conditions and high quality
forms allow for greater control of surface
finishes.
 We l e a d

• Type 1: Pre-cast Concrete

Framing, Panel and Box
Systems :
Plant-Cast Precast Concrete
• Structural elements are commonly
reinforced with tightly stretched
pre-tensioned steel strands, which
provide increased structural
efficiency.
• Conventional steel reinforcing is
added for resistance to thermal
and other secondary stresses.
 We l e a d

• Type 1: Pre-cast Concrete Framing, Panel and

Box Systems :
Plant-Cast Precast Concrete
• On the construction site, precast concrete
elements are lifted into place and assembled
into structural assemblies in a process similar
to that used for structural steel.
• Compared to site cast concrete, precast
concrete erection is faster and less affected by
adverse weather conditions.
Practical Example | Industrialized Building System
Pre-cast Concrete Framing, Panel and Box Systems
A vacuum lifting device is used to lift and place precast concrete pranks.
Practical Example | Industrialized Building System
Pre-cast Concrete Framing, Panel and Box Systems
3D Wall Panel System. Cool, fast, secured, save cost.
 Practical Example | Industrialized Building System
Pre-cast Concrete Framing, Panel and Box Systems

Other Precast Concrete Elements

Precast concrete stairs (below)
Uniquely shaped structural elements
for a sports stadium (right)
 TYPE 2 We l e a d

• Type 2: Steel Formwork Systems

• Considered as one of the “low-level” or the
“least prefabricated” IBS,
• As they generally involve site casting and are
therefore subject to structural quality control.
• The products offer high quality finishes, and
fast construction with less site labour and
material requirement.
 We l e a d

• Type 2: Steel Formwork Systems

• These include - tunnel forms, tilt-up systems,
beams and columns moulding forms, and
permanent steel formworks (metal decks).
Practical Example | Industrialized Building System
Steel Formwork Systems
 TYPE 3 We l e a d

• Type 3: Steel Framing Systems

• Commonly used with pre-cast concrete
slabs, steels columns and beams, steel
framing systems
• They have always been the popular choice
and used extensively in the fast-track
construction of skyscrapers.
 We l e a d

• Type 3: Steel Framing Systems

• Recent development in this type of IBS
includes the increased usage of light steel
trusses.
• …consisting of cost-effective profiled cold-
formed channels and steel portal frame
systems as alternatives to the heavier
traditional hot-rolled sections.
 We l e a d

Steel beams and

columns, portal
frames,roof trusses, etc

37
 TYPE 4 We l e a d

• Type 4: Prefabricated Timber Framing Systems

• Among the products listed in this category
are timber building frames and timber roof
trusses.
 We l e a d

• Type 4: Prefabricated Timber Framing Systems

• Timber building frame systems also have its
own niche market; offering interesting
designs from simple dwelling units to
buildings requiring high aesthetical values
such as chalets for resorts.
 We l e a d

Timber frames,
pre-fab timber
2
roof trusses, etc.

40
 TYPE 5 We l e a d

• Type 5: Blockwork Systems

• The construction method of using
conventional bricks has been revolutionised
by the development and usage of interlocking
concrete masonry units (CMU) and
lightweight concrete blocks.
 We l e a d

• Type 5: Blockwork Systems

• The tedious and time-consuming traditional
brick-laying tasks are greatly simplified by the
usage of these effective alternative solutions.
 We l e a d
Interlocking concrete
masonry unit (CMU),
lightweight concrete blocks,
etc.

43
 IBS - Topic Objectives: We l e a d

Understanding of:
• The concept of IBS construction project.
• IBS components.
• The category of IBS projects and
installation process.
• The handling of clients needs in IBS project
implementation.
 The category of IBS projects We l e a d

• IBS construction projects can be divided into

2 categories; Open System and Closed System.
• Open System: All IBS components are
obtained from various IBS manufacturers in a
construction project.
• Closed System: Building components are
based on exclusivity as they are manufactured
by a particular IBS manufacturer for a
construction project.
KL Convention Centre KL Tower
We l e a d

KL Central LRT Station

 We l e a d

IBS manufacturing and installation

process.
Production Flow (Part 1 of 2) We l e a d

Architectural &
Mix / Order
START Cast In Item (if
Concrete
applicable)
Failed

M&E Conduit
Mould Slump
Placement (if
Fabrication Test
applicable)
Passed

Rebar
Mould Set Up A
Arrangement
Production Flow (Part 2 of 2) We l e a d

Cured until
achieve the
Dispacth to
A required
strength Site
Failed

Cube Test
Concreting *(fci > 25
Mpa)
Installation

Cube Test
Lifting & Cube Test
*(fci > 15
Mpa) Stacking *(fcu > 40
Further Test (ie;
rebound hammer
Passed Mpa) / coring etc)
Failed Failed

Passed
Cured until
achieve the
required
strength END
 We l e a d

Reinforcement
Reinforcement
Bar
Bar, Window
Frame &
Conduit
Installation (if Windows &
applicable) Door Frame

M&E Conduit
 Concreting We l e a d

• Rapid All Weather Production

 De-moulding We l e a d

• Check against cube test result

52
Quality Check on Finished Products We l e a d
Storage We l e a d
 Logistic
We l e a d

• Dispatch to site

Just In-Time
method of
Installation (JIT)

• Crane Usage
depend on
tonnage of
element, site
accessibility &
arm length
 Installation We l e a d

• 1 Team = 4-6 Person

• Reduce site labour
 IBS - Topic Objectives: We l e a d

Understanding of:
• The concept of IBS construction project.
• IBS components.
• The category of IBS projects and installation
process .
• The handling of clients needs in IBS
project implementation.
 IBS Approach We l e a d

IBS APPROACH
CONVENTIONAL APPROACH

LAND
LAND
D
PLANNING
PLANNING
D
CIVIL CLIENT
ARCHITECTURAL PLAN ARCHITECT
STRUCTURE
D L
IBS METHOD
STRUCTURAL PLAN M&E QUANTITY
OTHER SERVEYOR
D CONSULTANTS

M&E PLAN
D SUBMISSION
SUBMISSION
D APPROVAL
APPROVAL D
D INSTALLATION
MANUFACTURING
IBS OF
OF
CONSTRUCTION COMPONENT CONSTRUCTION COMPONENT
D D
CCC CCC
D D

OCCUPANCY OCCUPANCY
Clients needs in IBS project implementation.
We l e a d

IBS advantages for Sustainable Construction

1. Safety
2. Labour Reduction
3. Productivity
4. Product Quality
5. Less wastage
6. Cost Effective
7. Time Savings
Quality: according to standards and specifications
towards sustainable construction We l e a d
Empire State Building –
Steel Frame We l e a d
 CONCLUSION: We l e a d

"Prefabrication does not mean to 'cut' an

already designed concrete structure into
manageble 'pieces'. Prefabrication starts
with the first drawings of a project. From
the start specialists are needed who are
acquainted with all the details of
prefabrication, from manufacturing to
finishing of the project." –

A.S.G. Bruggeling, G.F .HuYghe,

Prefabrication With Concrete
 Presented by
akmam@PPKA

THANK YOU FOR

YOUR ATTENTION…