CHAPT

ER 1

CC206
INDUSTRIALISED
BUILDING SYSTEM (IBS)
INTRODUCTION OF
IBS IN
CONSTRUCTION
INDUSTRY
Prepared by:
UMI HANI BINTI ABDUL RAHMAN
Politeknik Merlimau Melaka

Industrialised Building System (IBS)

1.
2.
3.
4.
5.

What is IBS?
Why IBS?
Types of IBS?
Challenges Faced by IBS
Advantages and Disadvantages of IBS?

1. What is IBS?
A construction technique in which
components are manufactured in a
controlled environment (on or off
site), transported, positioned and
assembled into a structure with
minimal additional site works.

1.1 History of IBS

Concept IBS is not new and can be traced back
to as early 1624.
In 1624, panellised timber houses were shipped
from England to the new settlement in North
America.
1851 Crystal Palace in Hyde Park, London and
1889 Eiffel Tower, Paris.

Crystal Palace, Hyde Park

During construction 1840

Picture taken in 1851

Eiffel Tower, Paris

During construction 1878

Picture taken in 1945

1.2 History of IBS in Malaysia

Concepts IBS in Malaysia is not new.
In 1966 the two pilot project started by using IBS
concept. Namely:
Pekeliling Flat, Kuala Lumpur
The Rifle Range Flat, Penang

In 1981-1993 PKNS acquired pre-cast concrete

technology from Praton Haus International,
Germany to built housing project.

Flat Pekeliling, KL

Public Housing in
Nusajaya, Johor

KLIA, Sepang

Masjid Besi Putrajaya

The Rifle Range Flat,

Penang

Menara Rebung, KL

1.3 Characteristics of IBS

5 characteristics of IBS are:
a) Industrial production of components though
prefabrication
b) Reduced labour during prefabrication of
components and site works.
c) Modern design and manufacturing
method using CAD/CAM.
d) Systematic Quality Control i.e ISO 9000
e) Open Building System i.e permitting
hybrid applications

2. Why IBS?
Budget speech 2005

2.1 The current Scenario of Malaysian

Construction Industry

This can contributes : Messy sites, High Wastage, Labour

Intensive, low quality and delays.

2.2 Social Problems

Currently 75 foreign workers out of 100
construction workers
There are 318,000 foreign workers in Malaysian
Construction Industry
Let say one foreign worker gain RM400/month
RM400 x 12 months = RM5,000/year
318,000 x RM5,000 = RM1.59 Billon/year
It shows the HIGH OUTFLOW OF RINGGIT

3. Types of IBS
In general, the construction method can be
classified into 4 categories:
a)
b)
c)
d)

Conventional Method
Cast-in situ
Composite Method
Fully prefabricated

Method b, c and d can be classified as non

conventional methods and all types of IBSs are
categorized under these three.

The construction method can be classified into 4

categories:

 Based on structural aspects, IBS can be divided

into 5 major types:
TYPE 1: PRECAST CONCRETE FRAME, PANEL & BOX
SYSTEMS

PC columns, beams, slabs, 3D-components

(balconies, staircases, toilets, lift chambers,
box girders, etc)

TYPE 2: STEEL FORMWORK SYSTEMS

Tunnel forms, beams and

column moulding forms,
permanent steel formworks
(metal decks), etc.

TYPE 3 : STEEL FRAME SYSTEMS

Steel beams and

columns, portal
frames,roof trusses, etc

TYPE 4: PREFABRICATED TIMBER FRAME SYSTEMS

Timber frames, pre-fab timber

roof trusses, etc.

TYPE 5 : BLOCKWORK SYSTEMS

Interlocking concrete
masonry unit (CMU),
lightweight concrete
blocks, etc.

4. Challenges Faced by IBS

Only 15% contractors using IBS, why???
a) Lack of Expertise / Lack of Experience
b) Cost
4.1 Lack of Expertise / Lack of Experience
c) Lack of experience practicing/designing IBS by the
consultants/contractors/clients
d) Short of experience workers in the manufacturing and installation works
(most of them are foreign workers)
e) Detect works by previous pre cast (close system)
f) QS lack of experience pricing the IBS projects (most of them not pricing
the total cost of project)

4.2 Cost
a) Only 15% contractors using IBS because the low labour cost
in this country is the root causes
b) Labour cost is cheap

5. Advantages and Disadvantages of

IBS
Advantages of IBS
a) Reduction of labor / unskillful workers
When the IBS components are produced in factory, higher degree of utilization of machine is
permitted and the use of labor will be reduced and lead to saving in labor cost. It is also will
reduce the construction process at site and consequently reduce the number of labor required at
site.
b) Reduce Wastage
The utilization of machine during the production of IBS components lead to higher degree of
precision and accuracy in the production and consequently reduce material wastage.
c) Increased in quality
An IBS component have higher quality and better finishes due to be careful selection of
materials, use of advanced technology, better and strict quality assurance control since
production in factory is under sheltered environment.
d) Safe working environment
Utilization of IBS components leads to less construction process especially wet work at site. This
will lead to the neater site condition and increase safety.

d)

Less construction period (time)

IBS requires less construction time because casting of precast element at factory
foundation work at site can occur simultaneously and the work at site is only the
erection of IBS components. This leads to earlier occupation of the building.

e)

Construction less affected by weather

Faster project completion due to rapid all weather construction. The effects of
weather on construction operation are less due to the fabrication of IBS
components is done in factory while at site is only erection of the components.

f)

Environmentally friendly
The use of IBS will decrease the using of timber formwork on construction
projects.

g)

Flexibility
IBS provides flexibility in the design of precast element so that different systems
may produce their own unique prefabrication construction methods.

h)

Cost savings
The formwork of IBS components are made of steel, aluminums or other materials
that allows for repetitive use and this leads to considerable costs savings.

Challenges and Lessons Learn Along the Construction Industry Value Chain

Disadvantages of IBS
a) Higher initial capital cost
The initial capital cost of IBS is usually high. The initial cost including the cost of constructing the
factory, casting beds and support machinery. The cost effectiveness can only be achieved when
undertaking large projects.
b) Sophisticated plants and skilled operator
The prefabrication system relies heavily on sophisticated plants, which have to be well coordinated
and maintained by skilled operators. Breakdown in any one section would hold-up the entire
production line.
c) Problem of joints
Water leakage is often the major problem in building constructed using IBS. This problem is more
obvious in Malaysia where raining occur rapidly throughout the year.
d) Large working area
Building construction using IBS requires a large working area for the factory, trailers, tower-cranes
and storage for the IBS components. Besides, most construction site especially in cities are often
congested and unable to provide the area required.
e) Site accessibility
Site accessibility is one of the most important factors of the implementation of IBS. IBS requires
adequate site accessibility to transport IBS components from factory to the site.