UNIVERSITI TEKNOLOGI MARA (UITM)

KAMPUS SHAH ALAM, SELANGOR

FACULTY OF ARCHITECTURE, PLANNING AND

SURVEYING (QUANTITY SURVEYOR)

CONSTRUCTION OF TECHNOLOGY III

(BQS502)

TITLE: INDUSTRIALISED BUILDING SYSTEM (IBS):

MASJID TUANKU MIZAN ZAINAL ABIDIN

NAME STUDENT (AP224 3A) NUMBER MATRIX

1. MUHAMMAD FADHLI BIN BAHAROM 2017169847
2.LIYANA HAJAR BINTI ALI 2017751617

3.NUR NADIA AFIQAH SANALI 2017348737

4.NURIN IZZATI BINTI ADLI MURAD 2017169941

5.RHENY SHAFEERA BINTI RAHIMAN 2017963313

 TABLE OF CONTENT

Table Of Content ................................................................................................................................. 2

Acknowledgement .............................................................................................................................. 3
1.0 Introduction ................................................................................................................................... 4
1.1 Introduction ................................................................................................................................. 4
2.0 Literature Review .......................................................................................................................... 8
2.1 Literature Review ........................................................................................................................ 8
3.0 Type of IBS Project ....................................................................................................................... 9
3.1. Project Background .................................................................................................................... 9
3.2. Type of Construction Method ................................................................................................... 12
3.2.1. Column ................................................................................................................... 13
3.2.2. Beam ...................................................................................................................... 14
3.2.3. Wall ......................................................................................................................... 16
3.2.4. Roof ........................................................................................................................ 18
3.2.5.Retaining Wall ......................................................................................................... 20
4.0 Comparison between IBS and Conventional Construction..................................................... 23
4.1. Comparison Between IBS and Conventional Construction ...................................................... 23
4.2. Advantages and Disadvantages between IBS and Conventional Construction ....................... 27
4.2.1. Advantages and Disadvantages between IBS ...................................................... 28
4.2.2. Advantages and Disadvantages between Conventional Construction ................. 29
4.3. Design ...................................................................................................................................... 30
4.3.1. Design Consideration ............................................................................................. 30
4.3.2. Design Procedure ................................................................................................... 31
4.4. IBS Systems Construction Procedure ...................................................................................... 32
4.5. Construction Process ............................................................................................................... 34
4.6. Transportation and Delivery ..................................................................................................... 35
4.7. Plant and Machineries Requirement ....................................................................................... 36
4.8. Challenges to Adption of IBS .................................................................................................. 39
5.0 Conclusion .................................................................................................................................. 42
6.0 Reference..................................................................................................................................... 43
7.0 Appendix...................................................................................................................................... 44

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 ACKNOWLEDGEMENT

First of all, we would like to thank Allah SWT as we are able to finish our assignment
that has been assign by our Construction of Technology III’s Lecturer, Mr Ahmad Arzlee Bin
Hassan. We had finally managed to finish up this group assignment with great enthusiasm
and determination. All the time we spent to do some research, went to the site and discuss
the ideas were worth our effort and time, InsyaAllah. Therefore, we would like to acknowledge
with a big thanks to the individual who guided us in completing our assignment. Firstly, we
would like to thank to our Construction of Technology III’s Lecturer, Mr Ahmad Arzlee Bin
Hassan. He always gives up support and guide us on how to complete this assignment
successfully. He also reminds and gives us guidelines on gaining the information about this
assignment. Then, we would like to thank to all of our friends who had helped and shared
ideas with us. They also gave us moral supports and advices. Last but not least, we would like
to show some appreciation to our parents who always prayed well for us and give us motivation
to keep on going and never give up. Not to forget, thank you to University Technology Mara
campus Shah Alam for providing a platform for us to gain knowledge and we would like to
appreciate Masjid Tuanku Mizan Zainal Abidin for letting us to do a site visit at their place. We
really hope our assignment is a success and can be accepted. We had used our effort and
acknowledgement to search all the information and ideas. We hoped our effort was worth it.

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 INTRODUCTION

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 defining as a set of interconnected element that joint together
to enable the designated performance of a building (Warswaski, 1999).

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. In another definition by Esa and
Nuruddin (1998) claimed that 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. (Junid, 1986) clarified that
elaboration of IBS whereby the IBS in construction industry includes the industrialised process
which the components are conceived, planned, fabricated, transported and erected on site.

The system balance combination between the software and hardware components.
The software elements include system design which study the requirements of end user,
market analysis, development of standardise components, establishment of manufacturing
and assembly layout and process, allocation of resources and materials and definition of a
building designer framework. The software elements provide a prerequisite to create the
conducive environment for industrialized building system (IBS) to expand.

The hardware elements are categorised into three major groups which are include
frame and beam system, panel system and box system. The framed structures are defined as
those that carry loads through their beams and girders to column and to the ground whilst in
panel system load are distributed through large floor and wall panels. The box system includes
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.

For this designated assignment, we choose Masjid Tuanku Mizan Zainal Abidin as our
location. The Second Mosque at Putrajaya namely Masjid Tuanku Mizan Zainal Abidin or
known as Masjid Besi (Iron Mosque). The construction of this unique mosque began in April
2004. It was known as ‘Masjid Besi’ because it was built by using six thousand tons of steel
with contributed more than 70% of the entire building.

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 The Architecture of the mosque lead by kumpulan Senireka under Dato Ar. Nik
Mohammad Mahmood and built by main contractor; Ahmad Zaki Resources Berhad. The
mosque is able to accommodate up to twenty thousand people at one time. The area of entire
Mosque covering more than 73,000 square meters and it built up to cater to approximately
24,000 the government servants working around the city centre and expected 28,420
residents as well as areas within Precincts 2,3,4 and 18 in the future.

The concept of the mosque is must be built in airy, light and transparent which make it
unique and recognise as a new modern architecture of mosque in Malaysia and not influence
by traditional concept and Mughal. The "Iron Mosque" features a district cooling system, and
without assembly of fans or an air conditioning system. The mosque employs "Architectural
Wire Mesh" imported from Germany and China, which is also constructed at the Santiago
Bernabéu Stadium in Madrid, as well as the Bibliothèque nationale de France in Paris. The
main entrance is reinforced with Glass Reinforced Concrete to increase the integrity of the
structure and uses fine glass to create an illusion of a white mosque from afar.

The mosque valued at RM 200 million is the only mosque in which it manufactures
using 6000 tonnes of iron or 70% of construction materials with a remaining 30% of
concrete. The main component of this mosque building is the mosque building and Kiblat Walk
which is a pedestrian linking the Perbadanan Putrajaya Complex (PJC) with Tuanku Mizan
Zainal Abidin Mosque.

These are a few pictures from our site visit;

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Page 6 of 46
Page 7 of 46
 LITERATURE REVIEW

From the article, it had been cited by H. Oğuzhan et. al., steel framework system,
usually lateral loads govern the design of tall steel buildings, particularly as a structural
system's height-to-width ratio rises. Steel buildings must therefore be intended and detailed in
order to be sufficiently rigid and stable to withstand lateral loads securely. The lateral loads
are resisted in such rigidly linked structures through flexural rigidity of beams and columns.
Another way is to strengthen a structural structure with a full-screw system that acts as a
vertical truss throughout the building's height.

Several studies in the literature have investigated design weight efficiencies of steel
frames featuring various types of beam-column connection and bracing configuration. The
literature study shows that the efficiencies of distinct steel frame works have been investigated
so far by comparing the design weights of the resulting structures when distinct framing
schemes are adopted.

On the other hand, it is common to anyone that a steel frame's minimum design weight
only ensures the highest material costs for members, yet it cannot ensure the lowest building
costs overall. It is highly essential to evaluate the design efficiencies of the various steel
frameworks on the basis of the building expenses of the resulting constructions rather than
design weights alone. In this respect, it is necessary to use a precise and realistic cost model
to determine the estimated costs of the de signs generated.

The rigidity and stability of the structural systems to the lateral forces is a major concern
in the design of high buildings, as high wind forces acting on the building's façades usually
cause important turning moments and lateral drifts. The steel buildings are therefore
incorporated with different framing technologies in order to create structures with adequate
lateral stiffness and drift index within acceptable boundaries. One framing scheme is a rigid
frame consisting of beam-column links that are moment-resistant (stiff). The lateral loads are
resisted by flexural rigidity of beams and columns in such a frame.

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 TYPE OF IBS PROJECT

TUANKU MIZAN ZAINAL ABIDIN MOSQUE

The Tuanku Mizan Zainal Abidin Mosque, or Iron Mosque (Malay: Masjid Tuanku
Mizan Zainal Abidin or Masjid Besi) is the second principal mosque in Putrajaya, Malaysia
after Putra Mosque. It is located in Putrajaya's Precinct 3, opposite the Palace of Justice.
Construction began since April 2004 and was fully completed on August 2009. It was officially
opened by the 13th Yang di-Pertuan Agong, Tuanku Mizan Zainal Abidin on 11 June 2010.
The mosque was built to cater to approximately 24,000 residents including the government
servants working around the city center as well as areas within Precincts 2, 3, 4 and 18.
Tuanku Mizan Zainal Abidin Mosque's area is twice that of Putra Mosque, which is located 2.2
kilometres north.

The construction of this unique mosque began in April 2004. Known as ‘Masjid Besi’
because it was built by using six thousand tons of steel with contributed more than 70% of the
entire building. The Architecture of the mosque lead by kumpulan Senireka under Dato Ar.
Nik Mohammad Mahmood and built by main contractor ; Ahmad Zaki Resources Berhad.

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 The concept of the mosque is must be built in airy, light and transparent which make it
unique and recognize as a new modern architecture of mosque in Malaysia and not influence
by traditional concept and Mughal. Three of these elements each were joined together on site,
with the result that they rise with the height of the facade and windows in an optically seamless
manner. Secured almost invisibly using hook bolts, they express the building contractors'
desire for simplicity, transparency and an openness to dialogue.

A modern interpretation of Islamic architecture, its 24m-high facade characterizes a

purist steel structure with typical geometric ornamentation. The rectangular openings of the
meandering structure are visually connected by a filigree facade made from 4,300 m2 of
stainless steel spiral mesh. Each mesh element is 7.70 m wide and up to 8.30 m long.

Depending on where that person is standing and where the light is falling, the fabric
mantle has a semi-transparent/opaque or a metallic, shimmering or even a monochrome, light-
grey appearance. Projecting shadowy outlines, they reflect mankind and nature in its
environment, distinctively conveying to the outside world the harmony of co-existence, which
is also represented inside the mosque by the common prayer. At night purposefully staged
lighting brings the transparency to life in a burst of illumination.

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 Natural air-conditioning In addition to this symbolic appearance, the robust,
maintenance-free mesh also fulfils extremely complex technical functions. The plans of
architect Nik Arshad Nik Mohammed made provision for natural air-conditioning in the main
prayer hall. In his draft he did away with glass windows and developed the idea of a mesh skin
acting as a protective membrane. The prevailing tropical climate in Malaysia with high
temperatures all year round and heavy rainfall in spring and autumn proved a particular
challenge in terms of finding a suitable material: the Escale 7x1 spiral mesh from GKD - Gebr.
Kufferath AG - met the high demands for both transparency and technology at the same time.

Corrosion and heat-proof, easy to maintain, non-flammable and resistant to

mechanical influences, the stainless steel mesh was chosen primarily for its almost unlimited
service life and low life-cycle costs. However, what was crucial in terms of its use was the
laminating effect of the mesh, thereby protecting against drafts while at the same time letting
the cooling wind penetrate the whole building as a pleasantly even flow. In this way
comfortable, natural air-conditioning which renders the use of air-conditioning systems and
fans superfluous, is created throughout the mosque.

Due to the window openings spread across the whole height of the facade, the mesh
is proving an effective means of protection against sun and rain. At the same time the
transparent woven structure, together with the soft radiance of daylight, underlines the
meditative atmosphere in the mosque.

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TYPE OF CONSTRUCTION METHOD

1.COLUMN

Column is a structural element that transmits, through compression, the weight of the structure
above the other structure above to other structural elements below.

 MAIN COLUMN (4’ x 4’)

I – Section steel column is encased with tile cladding and aluminum clad.

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 SECONDARY COLUMN (2’X2’)

Which is located near the safe area which is used to support long span floor beam for safe
area as the ablution area.

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2. BEAM

Beam is a structural element that is capable of withstanding load primarily by resisting

bending. The bending force induced into the material of the beam as a result of the external
loads, own weight, span and external reactions to these loads is called a bending moment.

 Podium level – A standard typical construction concrete beam which is 4 m high.

 Roof Beam – The vault steel roof truss that holds the steel roof and the main large long
span dome.

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How strong is the steel beam?

 Strength
Steel beam is given a mass that is capable of resisting much higher stresses without
fracture than an equivalent mass of wood or stone.

 Resistance to Corrosion
Stainless steel can be manufactured such way to be extremely resistant to rust and
corrosion. Stainless steel is a mix of steel and chromium. Thus, it has a much longer
life expectancy.

 Cost
Steel costs very little compared with other metals. This, combined with its other
mechanical and chemical attributes, contributes significantly to the popularity of steel
beams as a construction material.

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3. THE WALL

A wall is a structure that defines an area, carries a load, or provides shelter or security. There
are many kinds of walls such as defensive walls in fortification, walls of buildings which are a
fundamental part of the superstructure or which separate the spaces in buildings sections.
Building walls purposes are to support roofs, floors and ceilings, enclose a space as part of
the building envelope, along with a roof to give buildings form, and to provide shelter and
security.

 The wall at the staircase

 The wall from the entrance

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 The wall from ablution area

 the wall from exterior

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4. THE ROOF

The 40-feet-long edges of the mosque's roof are able to shelter the people praying outside of
the main prayer hall from rain. The dome structure is the main building and support all the
building. A dome is an element of architecture that resembles the hollow upper half of a
sphere.

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DETAILS OF DOME STRUCTURE

 HORIZONTAL BUILDING
The diagram above shows the horizontal loading of a dome. The major example of
horizontal loading is caused by wind. The latitudinal bands transmit the force created by
the wind around each side of the structure. The force is dissipated as it travels through.

 VERTICAL LOADING
This diagram shows us the vertical loading on a dome. Aside from the structure itself, snow
creates a large downward force on the dome. Like the wind force that travels horizontally
through the dome, this force travels longitudinally down through the structure.

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5. RETAINING WALL

 Cantilevered retaining walls are made from an internal stem of steel-reinforced, cast-
in-place concrete or mortared masonry (often in the shape of an inverted T).
 These walls cantilever loads (like a beam) to a large, structural footing, converting
horizontal pressures from behind the wall to vertical pressures on the ground below.
 Sometimes cantilevered walls are buttressed on the front, or include a counter fort on
the back, to improve their strength resisting high loads.
 Buttresses are short wing walls at right angles to the main trend of the wall. These
walls require rigid concrete footings below seasonal frost depth.
 This type of wall uses much less material than a traditional gravity wall.

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 The construction of this mosque estimates RM 200 million awarded to Ahmad Zaki
Resources Berhad. However, the awarded cost actually not included the foundation works like
piling and pilecap. Not many of us aware that the foundation works contract was awarded to
Pembinaan Mitrajaya Sdn Bhd under contract name “Cadangan Kerja Cerucuk Bagi
Pembangunan Sebuah Masjid, "Kiblat Walk" & Kerja Yang Berkaitan Dengannya Di Atas
Sebahagian P.T 116 (Plot 3V1 & 3OSV) Presint 3, Putrajaya” on 5 September 2003 with
contract sum RM 9,909,943.10.

The foundation cost only contributed 5% from overall construction cost of the “Masjid
Besi”. My Quantity Surveyor once said to me, "Just imagine in the engineering view can the
load of RM 200million seating on RM 9.9million as foundation". The original design of
foundation used to Bored piles type and it have been revised to Spun piles type by alternative
proposal in order to gain the contract. (Cost Reduce)

Bored piles are usually preferred over driven piles in limestone areas due to the following
concerns:

 Should there be cavities with roofs of inadequate thickness, there will be risk of
collapse of the roofs if piles bear on the roofs. Bored piles can penetrate through the
cavity roofs and socket a sufficient depth into the bedrock. The capacity of the bored
piles will be ensured. Bored piles also overcome the problem of premature termination
of driven piles on hard lenses, floaters or overhangs above bedrock.
 Due to erratic limestone rock surface, piles tend to deviate during driving although
provision of pile shoes and proper control of driving energy may be able to reduce this
phenomenon. Pile deviation results in excessive pile length and pile damages. Quite
often the integrity of piles can be affected without showing visible signs of damages.

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However, bored pile solution is costly and slow in construction compared to driven piles.
Stringent construction control is required to ensure the quality of bored piles. Due to the nature
of overburden material and limestone bedrock, difficulties can be encountered:

 Many ex-mining areas become dump grounds. Boring would be frequently hindered
by debris in the dump such as concrete blocks, steel bars, metal scraps etc.
 Bored holes are not stable when slime or very soft/very loose material, a common
feature of examining remnants is encountered. Although casing can be provided to
overcome this problem, collapses of bored holes are still possible as slimy soil can
enter the casing through gaps between the casing and uneven limestone rock surface.
There were cases where grouting treatments were needed prior to bored pile
construction due to the existence of slimy material.

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 COMPARISON BETWEEN INDUSTRIALISED BUILDING
SYSTEM (IBS) AND CONVENTIONAL CONSTRUCTION

Comparison Between IBS and Conventional Construction

The Industrialized 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 the definition by Construction Industry
Development Board Malaysia (CIDB), is building systems in which structural components are
manufactured in a factory, on or off site, transported and assembled into a structure with
minimal additional site works.

The IBS is an alternative approach of construction that will definitely charge the
scenario of the current local construction industry towards a systematically approach of mass
production of construction materials. IBS components of building which are conceived,
planned, fabricated from factories will be transported and erected on site. With this method,
the process would involve planning management and sustained improvement of the
production process to eliminate waste and ensure the right components are produced and
delivered at the right time, in the right order and without defect.

Conventional method is one of the construction methods that have been used over the years
and is popular method among contractors. This method is also known as traditional
construction method which uses wooden formwork. This method uses wooden or timber
framework. The components prefabricated on site through timber/plywood formwork
installation, steel reinforcement, ready mix/cast-in-situ concrete is costlier, low speed
construction time.

In term of speed and time, conventional method takes much longer than IBS method and it is
not environmentally friendly because normally it utilized timber as raw material where timber
can only be used 2-3 times as formwork. The conventional construction method is defined as
components of the building that are pre-fabricated on site through the processes or timber or
plywood formwork installation, steel reinforcement and case in-situ. The prefabrication takes
place at a centralized factory, thus reducing the requirement at the site. This is true especially
when high degree of mechanization involved.

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 Although, the conventional building that mostly built of reinforced concrete frames. The
traditional construction method uses wooden formwork. It is much more costly for construction,
which includes labor, raw material, transportation and low speed of construction time.
Nevertheless, Industrialised Building System (IBS) have lesser cost and higher speed of
construction if made a comparison with the conventional method. For the total number of
labour force required in the current IBSs, it is far lower than those required in the conventional
method of construction.

For the usage of heavy equipment, the IBS construction requires less use of heavy
equipment than that required for the conventional method of construction. This is due to the
fact that most of the IBS are of formwork, sandwich panel, block panel, and steel frame. These
systems do not require use of heavy equipment. The precast panel is the only system that
needs the use of heavy equipment during erection.

In terms of quality of the building, the IBS construction was found to be capable of
producing units of higher quality than what the conventional construction method could
achieve. However, the IBS need a much higher initial capital investment than does a
conventional system. This is because production facilities must be constructed and because
of the high cost of training labour.

The construction cost of a building using precast components should be assessed in

its overall context. The traditional method of costing by material quantities with a fixed factor
for labour cost can lead to incorrect estimation. For example, if labour usage is halved, this
will more than compensate for a 10% material increase.

Precast which is cast in one place, for intended use in another place, and is usually
mobile. Most of the production of components is carried out in a specialist factory, except in
cases where factors such as economy, geography, production scale and difficulty of access,
require the components to be cast on or close to the construction site. Regardless of
production location, the same managerial, supervisory and operational skills are employed.

More importantly, there is saving in time. Also, if properly designed and executed,
precast can lead to much better quality of work. The overall cost impact of precast has
therefore to take all these factors into consideration. With the rising costs of labour and less
assurance of dependable skilled manpower, the trend is that precast construction will become
increasingly competitive compared to cast-in-place construction. An industrialised building
system (IBS) allows flexibility in architectural design in order to minimize the monotony of
repetitive facades.

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Table 4.1: Comparison Between Industrialised Building System (IBS) Method and
Conventional Construction Method

FEATURES INDUSTRIALISED BUILDING CONVENTIONAL

SYSTEM METHOD CONSTRUCTION METHOD
 Time used for  Time taken around half of year  Usually taking 1-2 years to
completion of or less because shorter complete, depending to the
project construction period. scale of the project because
 IBS construction permits a longer construction period.
faster completion of the project  Delay completion of the
because of its rapid and all- project due to the on-site
weather construction. construction.
 The components are easy  Components are
assembled and erected. disaggregated and difficult to
assemble and erected.
 Costing  Cheap because the  A large amount needed for
components are produced in construction uses such as cost
factory thus reduce the for making formwork requires
wastage of cost for formwork higher cost in terms of:
and increases the cost savings  Material costs
as follows:  Labour costs
 Material costs  Equipment costs
 Labour costs  Overhead costs
 Equipment costs
 Overhead costs
 Quality and  An IBS component have higher  Low quality but the rare of
finishes of project quality and better finishes due finishes would affect with the
to careful selection of materials weather condition due to
and use of advance workmanship.
technology.  Requires a higher
 Provide higher quality and maintenance expenses
better finishes due to because of low quality.
production occurs under a
sheltered environment and
produced in the factory.
Better quality reduces the
maintenance expenses

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 because prefabricated
components require less repair
and preventive maintenance.
 Environmental-  The use IBS will decrease the  Less environmental-friendly
friendly and using of timber on construction due to high amount of timber
wastage project. used on construction.
 Wastage of timber followed by  Wastage of steel, followed by
cement, brick, soil and brick, cement, concrete and
concrete is less than 5%of the timber are close to 10% of the
total material used in the total material used in the
construction project. construction project.
 Problems of joints  Leakage is often the major  This method does not use
problem in building constructed jointing where the structure
using IBS. This problem is build manually and less
obvious in Malaysia where leaking problem occur.
raining rapidly occurs thought
out year.
 Reduce labour  All work is done by using  This method needs many
worker machine and only need few labour workers due to all work
workers that professional in are done manually.
IBS system.
 Size of the  Large working area needed for  Optimum working area
working area transfer and storage of IBS needed due to construction
component. done phase by phase.

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Advantages and Disadvantages between IBS and Conventional Construction

However, the application of prefabrication method in construction industry also has

advantage and disadvantage. The application of IBS in construction industry give benefits
such as better supervision on improving the quality of prefabricated products. That
prefabrication of building components can achieve better quality product by having better
supervision as the prefabricated products are tested and inspected before site installation.

Secondly, the IBS method can reduce overall construction cost if the standardized design
layouts are used at the early stage similar to the previous projects, on the performance in cost
reduction will be much better. Furthermore, the cost that can be saved from the early
standardized design layout, project duration can also be reduced as the prefabrication can
increase the productivity and efficiency of building construction.

In addition, IBS method in construction tend to produce less wastage compared to

conventional method in construction. According to CIDB (2009), the application of
prefabrication method will increase productivity, faster completion and requiring minimal
labour. Through IBS method, the components are prefabricated off-site. Thus, the construction
site is tidier and cleaner compared to conventional method.

Even though the IBS method is an environmental friendly technology but identified that there
are several hindrances (limitation of prefabrication technology) of applying IBS method in
construction industry such as temporary props may be required in some cases before the in-
situ concrete joints required achieve strength, some cracks may develop at the joints between
the precast and in-situ concrete due to temperature stresses.

In addition, in term of cost for formwork process, prefabrication method is more costly in short
terms nevertheless the cost will balance by the long term saving in timber formwork. Moreover,
project site adopted prefabrication method need more space to placing the prefabricated
building components. Assuming there is a massive amount of quantity - economies of scale-
wise, IBS systems will result in cheaper total construction costs, and buyers can benefit if the
savings are transferred to them.

As most components are manufactured in the factory, the quality, or rather high quality can
be consistent and maintained as the working environment in a factory is easier to control. The
wall surfaces, the soffit surfaces and so on can be controlled right to the millimetres in
dimensions, hence improved and consistent quality. Another good point for buyers is IBS
allows projects to be completed faster than conventional systems - due to the introduction of
pre-fabricated components to replace on-site works.

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Advantages and Disadvantages between IBS

Table 4.2.1: Summary of Advantage and Disadvantage Between Industrialised Building

System (IBS)

ADVANTAGES DISADVANTAGES
 Cost saving (long run)  High initial cost
-The formwork of IBS components that -The initial cost to invest in the IBS
mostly made of materials that can be used construction is higher as it requires specified
repetitively example steel or aluminium and machine to cast the components.
this reduces the construction cost.
 Shorter construction time  Requires highly skilled workers
-IBS speeds up the construction process -Although the numbers of workers are
because it requires less construction time as reduced, the quality of workers should be
the casting of precast element is done at maintained in a good range. IBS system is
factory only the erection of components that easy to assemble yet very risky to do so if
done at site. the workers are not properly trained.
 Reduction of unskilled workers  Prefabricated elements are inflexible
-The use of IBS reduces the construction -After the elements are constructed, the
process at site and consequently reduce the shape is hardly able to be changed as it built
number labour required on site. with high strength.
 Better site environment and  Transportation inflexibility
construction site cleanliness -Large IBS components might be a problem

-The IBS system reduces the wastage on to transport from one place to another and
site as the usage of formwork and tools has this will increase the construction cost and
been reduced. time.

 High quality and aesthetic value  Limited supply

-The quality of the IBS components has its -IBS system is not that famous in Malaysia’s
certain standard because it is prefabricated construction industry yet because not many
in a strict environment and has good manufacturers are available.
aesthetic value too as it is cast using steel
formwork and this creates a smooth surface.

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Advantages and Disadvantages between Conventional Construction

Table 4.2.2: Summary of Advantage and Disadvantage Between Conventional Construction

ADVANTAGES DISADVANTAGES
 The transportation is flexibility  It is produces in an unprotected
- It becomes an easy transportation (the wet environment
concrete) to access to the site must be -The impact on the community surrounding the
considered from the very beginning, as it will construction site can be significantly reduced,
need to allow for the delivery of large modules. due to much lower levels of noise and traffic
-Because the conventional construction during the project period.
method, from the early design to end. -The factory manufacturing process allows not
only for greater quality control during the
manufacturing process but for many health
and safety risks to be considerably reduced.
 It is flexible when it comes to geometric  Additional tie is required to the drying out
shapes process
- Concrete blocks is lightweight aerated block, -As major parts of construction are handled
can also be used for building foundations and within a factory, weather conditions are often
walls, but has a higher level of insulation and irrelevant during the majority of the project.
high level of strength and durability.
 It is relatively easy to do late changes to  It requires more temporary works (like
the structure propping) and takes longer process
-Conventional construction allows for later -Linear construction requires every step to be
design changes, while IBS construction is completed before the next can begin
unlikely to be able to factor these in, so early constructed.
complete design sign off is crucial with the -The construction process is more involved and
clients. can require hiring higher-skilled designers and
builders. This can add construction costs such
as materials and labor are more expensive.
 The structure becomes monolithic  Weather condition affect the quality
-When working with an architect, a consumer -Weather damage and inconsistent and labour
has choice and freedom to modify. The architect yield can affect the quality at the site.
has the option of creativity. Otherwise when Unfortunately, it becomes low quality.
more modern construction techniques are -Since all construction occur on site the
utilized, most homes are built in a similar style. schedule is dependent on weather conditions.

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Design Considerations

Structurally, the difference between conventional construction and IBS system is

structural continuity. In the case of the former, continuity is inherent and flows naturally during
the construction process. For the latter, conscious effort needs to be made to ensure this
continuity begins with the connection of the precast elements; the connections act as bridges
between the elements.

Thus, safety and stability should be the watchwords at all stages of construction, in
order to achieve a stable structural system. The successful implementation of the multi-
disciplinary techniques of pre-casting requires careful planning and synchronization among
the concerned disciplines (engineers, architects, general contractors and precast concrete
specialist subcontractors), through all design stages.

The decision to use pre-casting in construction needs to be made at the earliest of

design phases in order to allow for adequate coordination lead the time to allow for factory set
up of the precast elements should be sufficient. The pre-casting organization should be part
of the decision-making process to ensure design practicality and simplify production. Design
considerations are required to achieve high quality precast components.

Moreover, they include dimension and shape of precast elements such as concrete
components, moulds, reinforcements, joints and connections, loads, lifting and handling
devices, transportation systems and storage. Feasibility studies are required to assess the
capacities of the available transportation systems and on-site storage space, to ensure
adequacy.

As most components are manufactured in the factory, the quality, or rather high quality
can be consistent and maintained. Further to that, the standardization of building components
and elements also results in a lack of aesthetics value. Building tend to be very boxy and
square-y, which may not look as impressive as the conventional curvy building. But this part
here, IBS systems are being expanded to be more architecturally and eye-pleasing.

Compulsorily, the overall construction process must be properly established during the
early design stages. The design requirements for the erection/assembly of the precast
components must be done sequentially, with maximum tolerance. Product samples should be
set up to test product characteristics and quality (both on-site and offsite) for conformity and
standardization. Finally, and most importantly, last-minute design changes should be avoided
as much as possible, as they inevitably lead to increased expense.

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Design Procedures

There are four phases of designs which must be undertaken by the structural engineer
in the precast production process:
 Load assessment: Load estimates and tables must be set up.
 Calculation model:
 Definition of structural system
 Description of potential load path
 Assessment of the stiffness of elements and joints
 Method of execution and load combinations
 Structural analysis:
 Determination of the elements and joints loads.
 Evaluation of the carrying capacity/strength of cross-sections, joints and materials
 Comparison of loads and resistances
 Documentation: Specification, assembly drawings and calculation

Table 4.3.1: Structural Design Procedure (Building and Construction Authority, 2010).

PROCEDURES ACTIONS
 Load Assessment -Load table
-Load estimates
 Calculation Model -Structural System
-Load Path
-Stiffness of Components and Joints
-Joints
-Execution methods
-Load Combination
-Calculations: Internal Force, Reactions
 Structural Analysis (Codes of Practice) -Designs:
 Stresses
 Deformations
 Deflections
 Documentation -Specifications
-Calculations
-Drawings

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IBS System Construction Procedures

Conventional method construction imposes many restraints that usually result in time
penalties. The construction sequence begins from the foundations, followed by the supporting
structure, from floor to floor, up to the roofing system and then final enclosure. This system
usually entails a high level of erection and disassembling of formwork and false work.

Pre-casting reduces these requisites remarkably to decreasing time and affording the
client earlier return on investment (ROI) as discussed in the advantages of IBS System.
Whereas with pre-casting, once the foundation is established, the frame construction process
is easily carried out, and components are erected without framework or false work, except in
rare cases.

The structural concept behind precast components comprises:

 Conventional foundations (consisting of footings, rafts or piles)

 Cast in-situ ground reinforced concrete beam and slab system

 Precast concrete load-bearing walls:

 Precast concrete non-load-bearing façade panels

 Precast concrete floor system: precast concrete walls with precast concrete slab system or

precast concrete beams and slabs (with a composite in-situ top layer).

Foundation
The same foundation as used for conventional construction is used for pre-casting, the
difference being the arrangement below the load-bearing walls and that used for the normal
beam and column structural system. The aim is to have reasonably uniform support along the
wall’s length and reduce the effects of eccentricity should the walls be misaligned relative to
the foundations.

To achieve uniform support with a pile foundation, close spacing of the piles with a first
storey capping beam is adopted, although uneconomical. The proffered solution is the
designation of load- and non-load-bearing walls, locating the piles below the load-bearing
areas, using the first storey beam not as a capping beam but as a means of dispersing the
pile support along the wall, and finally grouping the piles to accommodate eccentricity.

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Ground Beam and Slab System
Precast construction is not cost effective or significantly advantageous over
conventional beam and slab system for the construction of the first storey, based on the
negligible cost of formwork construction and the significant extent of in-ground services.
However conventional construction will be beneficial in allowing extra lead time for the
production of precast elements, although there are possibilities to the use of precast system
for ground beams and slab.

Precast Load Bearing Wall

Precast load-bearing walls are more economical in comparison to conventional wall,
beam, column or infill system. They also provide better construction speed and eliminate wet
trades. Besides designing the walls as simple concrete members, there are several factors to
be considered in the design of the wall thickness, which include: joint details between panels,
connection details for supported slabs and beams, fire assessment and sound transmission,
and future services which could reduce the available concrete area. The recommended wall
thickness is 180mm based on characteristic building layouts and regulations.

Precast Non-Load Bearing Façade Panels

The non-load bearing façade components are usually the wall panels at the front and
rear elevations of a structure. For support, any of the following is implemented: connection of
the main load-bearing walls to the façade panel which is designed for self-support; or
connection of the façade panel to the floor slab or beam which is designed to support the wall.
Typical designs are for vertical loads due to self-weight and horizontal loads due to wind
forces, where applicable. 120mm is the recommended wall thickness to allow insertion of
windows and window profiles around the window’s boundary.

Precast Floor System

There are two kinds of systems for precast flooring: Prestressed Plank and Half-Slab
Floor System, and Precast beams and precast slabs. Both systems adopt structural in-situ
toppings. The former consists of prestressed planks spanning the load-bearing walls. The
latter comprises reinforced concrete half-beams which span between load-bearing walls and
half-slabs which span between beams. This system bears structural similarity to the
conventional reinforced concrete design.

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Construction Process

Once the design procedure for the components is completed, each component has to undergo
the following processes as:

1. Concrete mixing and movement from the mixing point to the mould.

2. Setting of moulds: the moulds are cleaned and oiled and the side frames are fastened.

3. Placement of fixtures, reinforcements, electrical components and such as will form part of

the components.

4. Casting: the concrete is poured, compacted and levelled.

5. Curing; naturally or artificially (by heating).

6. De-moulding: the side frames are stripped and the components are taken out.

7. Finishing, patching and repairing of the components.

8. Placement of the finished components in the stockyard for delivery strength.

9. Transportation of the components to the assembly site.

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Transportation and Delivery

The cost savings achieved by prefabrication are usually partially offset by

transportation costs from the factory to the project site. In addition, road transportation
regulations in certain countries may also pose as a barrier to the transportation of heavy
prefabricated panels. Such limitations ought to be given serious consideration prior to the
adoption of prefabrication.

It is of the essence that the delivery program is in sync with the erection cycle. As much
as possible, elements should be delivered into position directly from the transportation. The
usual process involves direct placement of the elements into the structure without turning or
on-site storage. Where on-site storage space is limited, considerations for offsite storage can
be made. Therefore, additional incurred costs should be accounted for.

However, site-stored elements are susceptible to damage and repetitive handling from
site stacking.

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Plant and Machineries Requirement

The erection and assembly of precast panels require heavy equipment such as cranes,
especially in the case of high-rise buildings. Such costs and operations need to be given
consideration in the case of implementation of prefabrication. A specialist team generally
carries out erection and assembly of precast components. The main operations are the
offloading, handling, installation of the components, lining and levelling of the cladding
elements, jointing and subsequent waterproofing of the whole structure.

The on-site lifting equipment and attachments must be similar to those obtainable at
the factory. Where necessary, specialized equipment have to be designed for circumstances
such as lack of headroom or access to already erected components. In the event of on-site
storage due to delay in delivery, appropriate stillages and racks are needed to prevent damage
to the precast elements. It is paramount that personnel are assigned responsibility for the
structural integrity of all fittings, connections and weather-tightness where cladding is involved.

In short, names of persons responsible for all erection operations need to be published where
quality assurance firms are employed. the safe lifting is important because moving
machineries can cause injuries in many ways. Some examples are:

 Workers in the construction site can be hit or injured by moving parts of machinery.
 Sharp edges can cause cuts and severing injuries.
 People can be crushed between parts moving in together.
 Poor or no maintenance of equipment can develop faults.
 Parts of equipment may fail or loads may drop.

To ensure that equipment is fully functional and hazard-free, make sure that the
equipment is safe for any work. Make sure that it is installed properly, is stable and is not in a
location where other workers may be exposed to risk. Choose the right equipment for the
appropriate job.

An industrialised building system (IBS) allows for faster construction time because
casting of precast element at the factory and foundation work at site can occur simultaneously.
This provides earlier occupation of the building, thus reducing interest payment or capital
outlays.

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 Appropriate measures such as using fixed guards to enclose the dangerous parts can
reduce risk and provide more protection. Fixed guards can be of secured screws or nuts and
bolts. There are also other methods such as the interlocking the guards so that the equipment
cannot be started before the guard is closed and cannot be opened while the machine is still
moving.

Figure 4.4 shows the fixed guards.

As some pre-cast components can be very large, cranes are used to lift these
components to put them in the desired place. There are a few types of cranes such as tower
cranes, mobile cranes and crawler cranes. Lifting hooks are installed at the top of the
components and lifted by the tower cranes through the hooks.

There should be a lifting plan supported by risk assessment. To eliminate hazards or

reduce risks, the lifting operation should be categorized with its risk level and complexity so
that suitable controls can be applied. A good lifting plan leads to less risk which means it may
lead to less cost due to faults or accidents. It also reduces the time to install the pre-cast
components, speeding up the construction process.

Table 4.4: Type of Plant and Machineries Requirement

TYPE EXAMPLE
 Cranes
Crane is a machine used to
lift heavy components and
transporting them to other
place or level.
Tower cranes Mobile Cranes

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 Crawler cranes

 Lifting Tools
Lifting tools or also known as
lifting gear is an equipment
attached to the crane that
can be used to lift and
lowering loads of the pre-
fabricated components.

Spreader Beam Wire Rope Slings

 Rigging Tools
Rigging tool example hook is
attached to the crane to
carry the lifting tools.

Hooks for the cranes Shackles (Lifting point)

Eye Bolt (Lifting point)

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Challenges to The Adoption of IBS

Construction sector is known to be a traditional sector that can be characterised as

reluctant and resistant to change.
- However, there has been a shift in paradigm regarding IBS in Malaysia for the past
few years. In the past, the majority of contractors were still divided between using the
IBS or the conventional method, in spite of the clear and eminent benefits of IBS. The
following are the main challenges encountered during the implementation of IBS in the
private sector.

Application of payments.
- Unlike conventional systems, typically, IBS manufacturers will impose an initial
payment or deposit to contractors for the purchase and delivery of IBS components.
Subsequent delivery of IBS components would also require immediate payments
(unless the contractor has a close work relationship with the IBS producers and can
negotiate for other payment terms).
- This may create cash flow problems to contractors as the project owner practises
payment methods based on conventional construction works whereby the structure of
a building is completed at the construction site. Whereas under the IBS method,
construction works will be done in the plant and the installation will complete at the
construction site instead.

Lack of knowledge.
- The bureaucratic system that is practised by some government departments and local
authorities (PBT) is complicated either on stage or in the planning stages of approval.
Some authorities still lack knowledge on the design process of IBS which has resulted
in misunderstanding or misinterpretation of the IBS construction.

High investment cost.

- Implementation of IBS costs is about 12-13% higher compared with to conventional
methods. This is due to the high prices of IBS components that can be broken down
to purchase of new machinery, manufacturing, tax and machinery imported from
abroad as well as cost of training workers for the installation of the components and
operation of various high-tech machines.

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- The high investment cost is also due to a mismatch in supply and demand for IBS
components as there is a limited number of IBS suppliers in the industry against the
backdrop of a rising demand for IBS components.

Break even on point.

- Although it creates more value to construction, industrialisation is literally a more
expensive option due to the high capital outlay and maintenance of machineries. On
top of that, inconsistency in business volume and lack of business continuity over time
may also result in the investment of the latest innovation not being commercially
sustainable.

The weak level of integration.

- Poor communication and poor coordination among project team members may also
contribute to the problem. Failure to understand the real needs of clients, as well as
providing incomplete painting of the IBS structure design have magnified the situation,
and thereby contributing to construct issues during the installation process on site.
- For example, some panels cannot be installed at the properly as the designated space
was initially reserved for doors, windows, lintels, etc. as such details were clearly
mentioned in the original design plan.

Design processes based on conventional practice.

- Most IBS projects were initially designed using conventional methods, but later
changed to the design of IBS. This usually happens when the contractor (who awarded
the project) discovers the manufacturer of IBS components. This will lead to wastage
of time and cost as such renovation works typically involves about 90% modification of
the original design plan.
- Hence, most consultants are not willing to redesign and convert all conventional
painting to IBS painting, unless the client is willing to increase consultation fees for the
additional work.

Shortage of skilled workers and limited training.

- Average programs offered for IBS design process at institute level especially diploma
and degree rank are currently still not recognized. Most programs still practicing their
conventional forms and guidance and not emphasize on such as pre-training to the
IBS components.

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Lack of standardisation in designs.
- So far, there has not been any standardisation codes in IBS project design works done
by consultants. Although the Modular Coordination (MS 1064) was introduced in the
IBS Roadmap 2003-2010 and 2011-2015, this code has garnered minimal participation
from industry players. Furthermore, most IBS manufacturers have their own respective
system which differs from one another in terms of size, type and installation method.
This causes problems to arise due to the inconsistency in design which complicates
the installation by the contractor at the construction site.

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 CONCLUSION

Industrialised Building Systems (IBS) is a construction process that utilizes techniques,

products, components, or building systems which involves mainly the prefabricated
components and onsite installation. Successful and effective implementation of IBS in
Malaysia construction industry can offer various benefits compare to conventional in-situ
systems. Those are the speed of construction, less wastage of materials which means cost
savings, reduction of unskilled workers, better quality control of construction, increased site
cleanliness and safety in construction projects.

In addition, these are very important aspects in achieving the efficient and effective
construction industry which will enhance the market share of construction industry as well as
contributing to the Malaysian economy. The government has done a lot of efforts to enhance
the current conventional, labour-intensive activities to a more technologically advanced
method of construction such as by developing the Industrialised Building Systems (IBS)
through the Construction Industry Development Board (CIDB). The government had efforts in
creating the Malaysia construction industry in producing fast, cost effective and high qualities
construction products and able to compete with the global construction market.

The conventional system is more cost saving as compared to IBS system since it
provides better negotiation chances so as to obtain the most competitive tender price
appropriate to the developer’s budget. There is also flexibility in choosing alternative building
materials at lower cost. Therefore, building cost can be reduced. As for the IBS, there are
limited to a few manufacturers or specialized contractors. This contributes to the higher cost
of building since a higher licensing cost is levied on the IBS panel and they tend to be
monopolized by the higher price of the building panel or other building components.

In a nutshell, IBS should be seen as an innovative improvement in the construction

industry. In industrialized construction, this innovation agenda has been promoted worldwide.
It is imperative that IBS is seen as an evolution of construction using new and innovative
techniques rather than a revolution. The classification of IBS should be expanded to cater the
scope of volumetric (modular) and hybrid construction. IBS is not to be seen as a threat to
traditional methods. Both methods should be able work in tandem and improve their processes
collectively. The usage of both method constructions is important to ensure that the
construction industry will obtain the best benefits from both systems.

Page 42 of 46
 REFERENCE

Alexis. (2019). Traditional Construction Techniques. Retrieved from eHow Discover:

https://www.ehow.com/how_6033035_buy-laser-engraving-machines.html

Anon. (2010). Industrialised Building System (IBS) Versus Conventional Building Method. Retrieved
from Scribd: https://www.scribd.com/doc/202795797/Ibs-vs-Conventional

Anon. (2016). The Conventional System And Industrialized Building System Construction Essay.
Retrieved from UK Essays: https://www.ukessays.com/essays/construction/the-
conventional-system-and-industrialized-building-system-construction-essay.php

Anon. (2019). Why Choose Conventional Construction. Retrieved from Smart Building:
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Guang, H. Y. (2014). Industrialised Building System (IBS). Kuala Lumpur, Malaysia: Taylor's University.

Iyah, O., & Yuyu, E. (2012). A Comparative Evaluation of the Environmental Impact of Prefabrication
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Nazziera, S. (2011). Types of Construction Project in Construction Industry. Petaling Jaya, Kuala
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Page 43 of 46
 APPENDIX

Site Visit

Photo shows that we (group members) had site visit at the Masjid Tuanku Mizan Zainal
Abidin,Putrajaya. We interviewed staff at there that are Encik Shafiq, Assistant Civil Engineer
and Cik Bariah from Facilities Management.

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Award

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Assignment Brief

Letter of Site Visit

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