Canadian Journal on Environmental, Construction and Civil Engineering Vol. 2, No.

1, January 2011

Development of Production Rates Database System for IBS components in Malaysian Construction Industry
Arazi Bin Idrus, Sana Muqeem, Saiful bin Zakaria and Wira Azizi Civil Engineering Department Associate Professor, PhD Student, Masters Student, Undergraduate Student Universiti Teknologi PETRONAS 34500 Bandar Seri Iskandar, Tronoh. MALAYSIA Email: arazi_idrus@petronas.com.my, sanamuqeem@yahoo.com, saifulsshi_sa@yahoo.com.my, wiraazizi@gmail.com

Abstract Due to the declining productivity in the construction industry, the Malaysian government has embarked on a serious program to promote the use of Industrialized Building Systems (IBS) to improve the performance of its construction industry. One aspect to improve is in the planning of IBS projects. Efficient planning of IBS works requires, among others, reliable data on production rates. Currently, there is hardly a database of production rates for use by construction planners in the country. This study aims to develop a database of production rates for IBS works. Production rate of IBS components in this research is focused mainly on the installation rate of these components. To obtain a significant number of reliable data, quantitative measurements have been done using work sampling approach. The result of this study may be used as a tool to estimate the installation rate of IBS construction projects. Keywords: IBS components, Production rates, Work sampling, Descriptive statistics Introduction Due to the declining performance of its construction industry over the last decade, the Malaysian government, through its agency the Construction Industry Development Board (CIDB) has put plenty of efforts to enhance the current conventional labor intensive activities towards more productive and technologically efficient methods of construction. This is being done so that Malaysia is capable of producing fast and high quality projects and able to compete at international level. For this, one of the main approaches taken is to promote the use of Industrialized Building Systems (IBS) as an alternative to conventional in-situ systems. IBS is a construction process that utilizes techniques, products, components, or building systems which involve prefabricated components and on-site installation [1]. Compared to traditional in-situ, they are much faster and safer to erect, have higher quality finishes, and use less labor and, if properly executed, will result in significant cost savings. However, despite the theoretical advantages, and promotional efforts taken by the CIDB, the current market share for industrialized building systems in this country is generally still small. A survey conducted by the CIDB [2] showed that industrialized systems only share about 15 % of the total building market. The figure has not changed much since then. Among the reasons that prevent the wider use of industrialized building systems are uncertainties of engineers regarding the advantages and disadvantages of such elements, particularly in terms of cost

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and speed as well as the widespread 'lack of knowledge' among engineers in the planning, design and construction of these systems [3]. Project planning relies on availability information such as scope of work, sequence, quantity, and activity durations, which depend on production rates assumed. Currently, there is no published database of production rates for IBS construction for reference of project planners in the country. The development of a reliable database of production rates would enable a more accurate prediction of activity durations and hence would facilitate efficient planning of industrialized building systems construction. Moreover, the establishment of a production rates database has been recommended by researchers for more accurate use of productivity measurement system [3]. The paper aims to report on the development of a production rates database for Industrialized Building Systems works Malaysia. The research focused on installation rates of structural elements for Framing and Panel types of Industrialized Building Systems. Although IBS has introduced to increase the construction efficiency, however there is no specific database of production rates developed for construction reference for the IBS projects. Even though there are surveys questionnaire have been done in Malaysia that provides only the description of societys perceptions on IBS [4], [5]. Methodology Researchers have identified that suitable method of data collection influenced the accuracy of the production rates values. Questionnaire survey is the most commonly used method of data collection usually adopted by the researchers to collect information on factors and production rates in a cost effective way but the reliability and accuracy of the results cannot be proved. In order to get accurate value of production rates, work sampling approach has been proved to be reliable method of data collection in which rates are measure directly in the field. Work sampling is the technique used for data collection that observes the labor activities at fixed predetermined intervals [6]. It has been identified as the most relevant and authentic method for measuring and evaluating productivity performance on site. It provides prcised, detailed and real time information on production rates [7], [8]. Therefore, work sampling approach has been adopted for measuring production rates for IBS components in this research. Before going to the field, a standard data collection forms has been constructed to record the data. Form contain the production rate, the number and types machineries used, the weather chart, number of labors, working hours and the erection activities. During the field observations, the time taken to complete each activity is recorded and the numbers of installation units for every concrete prefabricated component are determined to obtain the production rate. The activities include columns, beams, wall and slabs. Stopwatch is also used to record the duration for each activity in installing the IBS components. The data obtain from four (4) different project sites and then being analyzed using descriptive statistic. The installation rate is calculated for each steps of installation. To achieve significant confidence level at least thirty (30) readings have been managed to be taken per activity to obtain mean, median and mode of the sample data. Potential outliners that could result variation in the data are identified and frequency distribution graphs are also plotted to 90

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determine the pattern of data distribution. Finally, the moderated rate for each activity has been determined. Possible sources which lead to the result variation between the four sites are also explained in this paper. Result and Discussion Production rates data has been taken from four different projects as mentioned above. Project Sites Observed Figure 1 shows the distribution of project sites the author has visited for data collection. There are four (4) projects that have been visited for data collections. Two sites are located in Perak, one site in Kuala Lumpur and one site in Negeri Sembilan. All of these projects are JKR (Jabatan Kerja Raya) Government based owned project. Figure 1 shows the distribution of different project sites in Malaysia. Brief description of each project site is given below.
Site

PERAK 50%

NEGERI SEMBILAN 25% KUALA LUMPUR 25%

Figure 1: Different Project Sites in Malaysia

Perak Both of the projects chosen for data collection in Perak involve Type 1 IBS Panel System. The first project is SJK (T) Sangeetha Sabah, Ipoh, Daerah Kinta which is consisting of four (4) stories building. The second project is SJK (T) Matahma Ghandi, Sungai Siput, Daerah Kuala Kangsar that consist of 3 stories building. Both projects are awarded to the same main contractor and IBS installer. Figure 2 and figure 2 shows the sites location that has been visited in Perak.

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Figure 2: SJK Mahatma Ghandi, Sungai Siput.

Figure 3: SJK Sangeetha Sabah, Ipoh.

Negeri Sembilan The third project is related to the construction of SMK Pedas boarding school in Mukim Pedas, Daerah Rembau, Seremban, Negeri Sembilan. This project involve the construction of a secondary school comprises of 3 stories building and 3 blocks using Type 1 IBS Framing System. Figure 4 below shows SMK Pedas project site located in Seremban, Riau.

Figure 4: SMK Pedas, Seremban.

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Kuala Lumpur The project in Kuala Lumpur involves the construction of 11 stories building for Faculty of Built Environment in University Malaya institution of higher learning. This project also used Type 1 IBS Framing System. The IBS installer that handled this project is the same who has handle SMK Pedas in NEGERI SEMBILAN although different contractor involved. Figure 5 below shows the project site of Faculty of Built Environment in UM.

Figure 5: Faculty of Built Environment, UM.

This research study has mainly focused on academic building projects such as schools and university faculty buildings because academic buildings usually have different architectural design with large repetitive element. The production process for element of such building characteristics can be manufactured in numerous numbers thus will reduce the overall cost of production. Data Analysis Author has interpreted the raw data by descriptive statistics to explain the data characteristics. Three major criteria have been used includes frequency distribution, measure of central tendency and measure of dispersion. In examining the data distribution, the author had plotted frequency distribution histogram and computed box plot analysis. Box plots are computed to determine any outliners in a data sample. In Table 1 measure of central tendency such as mean, median and mode of each activity calculated is shown. For calculating measure of dispersion of data in the data sample, standard deviation is determined to represent the spread of values. Summary of the analysis of production rates calculated using descriptive statistics is shown in Table 2.

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Table 1: Descriptive Analysis of Production Rate.

PANEL SYSTEM

Unit

Mean Mode

Standard MAX Min Lower Lower Upper Upper Lower Count Median Deviation value value Whisker Quartile Quartile Whisker Outliers WALL PANEL 2.835 23.136 7.852 3.366 3.890 5.295 1 0 0

Overall Installation Overall Installation Overall Installation

m/manhr 3.265 3.890 0.984 5.295 0.569 56 1.364 SLAB m /manhr 33.164 37.500 14.387 82.364 6.487 114 6.487 CROSS BEAM m/manhr 10.495 #N/A 4.069 16.667 2.853 15 2.853
2

30.192 40.111 63.663 12.172 13.142 16.667

Table 2: Summary of Moderated Rate

PANEL S YS TEM

Unit WALL PANEL m/manhr S LAB m2/manhr CROS S BEAM

M oderated Rate 3.265 33.164 M oderated Rate 26.606 8.018 0.123

Overall Installation Overall Installation Overall Installation FRAMING S YS TEM Overall Installation Overall Installation Overall Installation

m/manhr Unit S LAB m /manhr BEAM m/manhr COLUMN m2/manhr

2

Installation of Wall Panel Histogram has been drawn for installation of wall panel activity as shown in figure 6 below. It indicates that the distribution is almost normal. The value of mean, mode and median for this activity does not differ much between each other. This activity represents lifting, leveling and prop installation. However, when readings are taken, the author only recorded the time required for transporting the IBS components. The installation rate would have been more accurate if the author had recorded the idling time and also the time when the crane is in motion, moving from one place to the other. 94

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Figure 6: Overall Installation for Wall Panel histogram

Figure 6 shows that the distribution is almost normal therefore, in this case, the best judgment is to use mean as the moderated rate. Slab Overall Installation Similar to wall panel installation, slab overall installation also combines lifting and leveling together.

Figure 7: Overall Half Slab Installation histogram

The histogram shows in figure 7 mean for moderate rate in this activity persist to be used because no significant difference exist between median and mean. The histogram is slightly skewed to the right. Therefore the median value is less than the mean value.

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Cross Beam Overall Installation Panel System does not use a lot of beam because the wall panels already act as a load bearing to resist the load. However, there are some cases for example when a large hall or room is needed when more beams can be used. In that case, cross beams have to be design to support the slab which are design in a standard dimensions.

Figure 8: Cross Beam Overall Installation histogram.

No accurate conclusion can be drawn as the number of sample collected in this activity is not enough to get moderated value of production rate. Overall Installation for Hollow Core Slab (Framing System) The overall installation for hollow core slab includes lifting and leveling of the slab. Since, both activities only require a short period of time, there is no point in calculating each activity separately unlike panel system.

Figure 9: Hollow Core Slab Overall Installation histogram

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From the histogram shown above in figure 9 it can be seen that the data is normally distributed. The value for mean, mode and median does not varied much between each other, so the mean is subjected to be used as the moderated rate for this activity. Beam Overall Installation Precast concrete beam in both sites with framing system utilize pretension beam to support the hollow core slab. There are two (2) types of connections for beam-column joints. Most of the beams are just resting on the column corbel and the other type is BSF knife plate system.

Figure 10: Beam Overall Installation histogram.

BSF Plate consists of a steel box cast inside the column and at the beam end. The steel box cast into the beam contains load bearing plate or knife. During erection, the load bearing plate will extent outwards and slot in the corresponding steel box at the face to the column. This system offers a completely hidden connection that is good for aesthetics and it also erect quickly because there is no bolting or welding on site and it also reduces space requirements for storage. The distribution on the histogram as shown in figure 10 represents the data is normally distributed. There is not much difference observed in the values of mean and median as indicated in Table 1. Therefore, the mean is taken as the moderated rate. Column Overall Installation (Framing System) Column overall installation covers lifting, leveling (shim placement) and propping of column. The author only managed to record the overall time because some of the activities like leveling and propping are usually overlapped with each other. So it is easier to take the time spend to install the column than to calculate the activity separately. At least two (2) props are installed depending on the weight and height of the column. Prop installed must be in perpendicular direction with each other.

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Figure 11: Column Overall Installation histogram.

The base area of the column footing is measured with the unit meter square (m2). From the histogram shown in figure 11 it is indicated that the distributions is not normally distributed. The highest frequency is recorded to be in the range of 0.137 to 0.15. Therefore, mean is taken as the moderated rate because the value is closer to range with highest frequency. Conclusion and Recommendations Four project sites have been observed for collecting production rates of IBS component for panel systems and framing systems. Production rates for wall, slab, beam and column installations have been measured. Descriptive analysis of the rates has been done which indicates slightly variation in the production rates values of slab installation as compare to other components. Mean is taken as a moderated rate for wall, beam, slab and column installation. Author had successfully obtained the productivity for all activities involve in panel system and framing system. At the end it can be concluded that the authors have been able to successfully achieve the objectives of this research by developing reliable production rate database system for IBS installation system to be used by the estimators in future. For future research on the IBS productivity, the author would recommend to include together the time when the crane is idle. From the author point of views, there were many factors that could affect the productivity of IBS construction, but one of the very common factors is the lead time. In IBS lead time are often cause by the waiting for the precast components to arrive at the construction site. Hence for future research, the errors in the result obtain would be further minimize if the idle time or lead time is also considered. It will be useful if the moderated idle time in each activity is known for IBS installation. It has also been recommended that the future research should also includes method of box system of installation IBS to completely obtain type one IBS system.

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Acknowledgement I would like to thank first of all to Allah Who gave me the capability to do this research. I am also very thankful to my colleagues for their help and support in the field work. References [1] [2] CIDB Malaysia, IBS Roadmap 2003-2010, pg 7 14 ; Holly, Anubhav and Patrick. IBS Roadmap 2003-2010.CIDB Malaysia, IBS Survey 2003: Survey on the Usage of IBS in Malaysian Construction Industry. S. Elliott, 2002, Precast Concrete Structures. Butterworth Heinemann A.Idrus, N.F.K.Hui and C.Utomo (2008). Perception of Industrialized Building System (IBS) Within the Malaysian Market. University Teknologi Petronas, Malaysia. A. Idrus, Sana Muqeem, Faris Khamidi, Zairul Aziya, 2010. Development of Production rates database for Pre-cast construction works. International conference on construction and project management. China. M.W Emsley, F. C Harris 1990 Methods and Rates for Structural Steelworks Erection. Technical Information Service. A D F Price, 1991. Measurement of Construction Productivity: Concrete Gangs Technical Information Service. Simon D. Smith, 1999. Earthmoving Productivity Estimation using Linear regression techniques .Journal of Construction Engineering and Management. Vol 125, No .3.

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