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IBS 101 by Innovacia
Introduction to Industrialised Building System (IBS)
and Precast Concrete
incorporating
IBS Score based on CIS18: 2018 and MS1064: 2018
Ir. Shahrul Nizar Shaari
Hj. Abu Saffian Abu Bakar
Innovacia Sdn Bhd Version 200120 www.innovacia.com.my
About IBS 101
This document is prepared as an introduction reference to IBS and IBS Score; based on the latest CIS18: 2018 and
MS1064: 2018.
Join the Free* CIDB IBS Professional Training organised by Innovacia for richer content and to gain better understanding
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Ir. SHAHRUL NIZAR BIN SHAARI, B.E. (Hons) Civil, M.B.A, P. Eng
Possessing hands-on experience in IBS execution, Ir. Shahrul started his career at an IBSmanufacturer/contractor, ACPI Berhad (now known as AlloyMTD Berhad), in 1997. Hewas in the factory set-up team for three IBS factories and later joined the designteam; and was involved in numerous IBS projects including Serdang Hospital, IntanBukit Kiara, One Utama, teachers quarters and schools. He was in the team that wonthe CIDB’s maiden Best IBS Project Award (now part of MCIEA) 2001.
In 2002, he joined CIDB Malaysia and was involved in the formulation of the first IBSRoadmap and many early technical publications and events on IBS including the IBSScore Manual and IBS Survey 2003. After short stints at Parlimen Malaysia and UEMWorld, he founded Innovacia in Nov 2006 to provide IBS training services; the firstprivate company accredited by CIDB.
Since 2007, he has led >300 construction technology courses; including train-the-trainersessions for numerous government training houses. Among the IBS relatedconsultancy projects include Cost Benefit Analysis (CBA) for IBS Industry forCREAM/CIDB, Economic Order Quantity (EOQ) Study for MPC, IBS Project Pre-Inception Consultancy for MIGHT, IBS Industry Market Assessment in Qatar for UEMBuilders Bhd, numerous research papers as well as fifteen IBS Training modules(Contractors & Installers) for CIDB and CIDB MyIBS.
He leads Innovacia in becoming a MATRADE member (Malaysian exporter) since 2012and has expanded its products & services to cover ICT Solutions. In 2012, thecompany was among the Top 3 Finalists of the NEF Astro Awani ICT Awards for theMost Innovative Company. Its popular app, Site Report, was featured in the GulfNews (Five Advances in Construction Technology) during the Big5 Expo, Dubai in2014. Besides producing mobile apps under Innovacia Mobile, Innovacia is the brandowner of Malaysia's first CAD/IBS software, TiffinCAD; and TiffinBIM. Major usersinclude Malaysia Polytechnics, SYABAS, MBSA and many other organisations.
Latest products by Innovacia include Innovacia VR/AR (Virtual & Augmented RealitySolutions), Innovacia IoT Info-Feeder System and Axdea (BIM-based IBS ScoreSoftware). Innovacia's construction technology magazine, binaTECH, is now a mediapartner for many international expos including Konstruksi Indonesia, Buildtech AsiaSingapore, Concrete Asia Thailand and Ecobuild SEA KL.
Ir. Shahrul is also active in many technical committees including for MS 1064, CIS 18 IBSScore as well as NOSS & WIM for IBS Manufacturing and Installation. He is also aregular invited to present papers at i-KPKT, JKR’s CREATE, CIDB, CIDB Holdings and theMalaysian Polytechnics.
HJ. ABU SAFFIAN ABU BAKAR, B.E. (Hons) Civil
Abu Saffian Abu Bakar has 30 years of progressive management work experience.Former Senior Vice President at Agensi Inovasi Malaysia. Prior to AIM, he worked atIskandar Investment, ACPI and IJM. With vast experience in IBS, businessdevelopment, project mgt, property dev, manufacturing, sales & marketing andquality management systems.
Highlights of his vast IBS experience includes involving in precast concrete and steelstructures executions. Responsibilities include the making feasibility reports, theprocurement and setting up of the manufacturing facilities, managing the businessactivities – sales & marketing aspects, operational efficiency and financialperformance.
Planned, developed and implemented the business strategies for the companyinvolving new products. The company has achieved steady growth with total salesof: Over 2 million sq.m of precast concrete half slabs for floors, 700,000 sq.m ofprecast concrete blocks and 25 million concrete roofing tiles.
Developed the technical aspects of the building system - Permanent ConcreteFormwork that won the inaugural CIDB award in 2001 for the best IndustrialisedBuilding System.
Team leader for the submission of the privatisation proposal for 10,000 units ofTeachers Quarters to the Government – we were granted a Letter of Intent for 2,000units as a result of our excellent performance in completing 100 units against 20other competitors.
Led and directed the construction, completion and commissioning of three high-risecondominium blocks at Vista Komanwel, Bukit Jalil that housed the athletes for theCommonwealth Games in 1998. Also in charge of the business performances of C&GFabricators Sdn Bhd, Universal Building Products Sdn Bhd and Acentis EngineeringSdn Bhd. These wholly owned subsidiary companies are in the businesses of steelroof trusses, metal door and window frames and packaged precast concretesewerage treatment plants respectively.
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Smart applications that are relevant through
2025
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Lunt Fort, Coventry
AD 43 Prefab Roman Timber Forts
43
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1579 Nonsuch House Holland to England
No nails
1624 Panelised Wooden Houses England to New England
1624
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Late 1700s To Australia & South Africa
1833 Henry John Manning Portable Colonial Cottage
First documented house
1833
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1851 Joseph Paxton's Crystal Palace
1851
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1960 Danish Open System
1960
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1968 BES – Finnish Open System
1968
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1966: Pekeliling Flats
1969: Rifle Range Flats
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IBS in Malaysia
2004 2005 2006
2007 2008 2009 20152003
MS 1064: Modular Coordination as Guideline for Building Design
IBS Roadmap 2003-2010
Manual for IBS Content Scoring Diterbitkan
Circular issued on IBS by Treasury on 25 July 2005
“Encourage”
Follow-up Treasury Circular on IBS issued on 31 Oct 2008
“Mandate”
1999
IBS Strategic
Plan 1999
IBS Roadmap Review 2008-2010
2010
Malaysia IBS International Exhibition ’06 (MIIE06)
Diluluskan oleh Kabinet
Construction Industry Master Plan2006-2015
Malaysia IBS International Exhibition ’09 (MIIE09)
IBS Roadmap
2011-2015
2001
Approved by the
Cabinet on 9 July 2010
Manual for IBS Content Scoring CIS18 2010: Diterbitkan
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THE TARGET
Increase of productivity to
US$16,500 per
worker(2.5x using 2011 as a base)
Projek kerajaan :
RM10 juta ke atas – 70 IBS Score mulai 2017
Projek swasta:
RM50 juta / 50,000 m2 ke atas – 50 IBS Score
2018 – PBT Lembah Kelang
2020 – Selangor, Penang & Johor
Pengecualian levi untuk projek perumahan – 50
IBS Score
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Definition of 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.
- CIDB 2003
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Innovative Systems
Precast Concrete Blocks Steel Frames
Formwork SystemsTimber Frames
PEMAKLUMAN PERLAKSANAAN IMPACT
4. Pengeluar yang telah memperolehi pensijilan AIS serta masih dalamtempoh sah pendaftaran, tidak perlu memohon untuk mendapatkan persijilanIMPACT dan boleh menggunakan pensijilan AIS yang ada sehingga tamattempoh. Walau bagaimanapun, pengeluar tersebut hendaklah membuatpermohonan melalui IMPACT apabila pensijilan telah tamat tempoh. Adalahdinasihatkan pengeluar yang telah memperolehi pensijilan AIS untukmengemukakan permohonan IMPACT dalam masa 30 hari sebelum tarikhtamat pensijilan AIS.
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Faster Better Cheaper
Higher productivity per worker, controlled quality,
more archi options, unpropped options, less site
workers/materials, less wastages, higher safety,
less rework, faster completion, real costing, lower
total construction cost
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Expensive (?)Transportation
Precise MeasurementPractical Detailing
CoordinationTrained Workers
Plant Design / Production FlowEarly Planning
Changes
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Cost Benefit Analysis
MonetisableRM 21.8111 billion
Benefits RM 103.4964 billion(after inclusion of hypothetical increase to private consumption, reflecting higher
salaries & wages as a result of fewer foreign workers)
Costs RM 81.6853 billion+
Quantifiable+
Qualitative
Business Perspectives
Socioeconomic & Political
Perspectives
Public Admin & Governance Perspectives
Sustainability, Safety & Health
Perspectives
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Basic Principles
1. Basic module, 1M = 100mm
2. Vertical plane basic module = 1M
3. Horizontal plane basic module = 3M
4. Preferred sizes – MS1064
5. Submodules of 3M = 150mm (1/2), 100mm (1/3), 75mm (1/4),50mm (1/6)
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MS 1064 : 2001
PART 1 : General Principles
PART 2 : Storey heights and room heights
PART 3 : Coordinating sizes and Preferred sizes for stairs and stair
openings
PART 4 : Coordinating sizes and Preferred sizes for doorsets
PART 5 : Coordinating sizes and Preferred sizes for windowsets
PART 6 : Coordinating sizes and Preferred sizes for rigid flat sheets
PART 7 : Coordinating sizes and Preferred sizes for tiles
PART 8 : Coordinating sizes and Preferred sizes for masonry bricks &
blocks
PART 9 : Coordinating sizes and Preferred sizes for cabinets
PART 10 : Coordinating sizes and Preferred sizes for reinforced
concrete components
Table 1 : Dimensions of preferred sizes for doorsets
Door
Single leaf
Single leaf and side leaf
2100
2100
Height Width
800900
1200
Double leaf
Sliding door
15001800
1800
2100
2100
Part 4 :
Table 1 : Dimensions of preferred sizes for windowsets
600
1200
Height Width
600120018002400
120018002400
1800
2400
Part 5 :
Table 5 : Dimensions of preferred sizes for reinforced concrete beams
Types of buildings
Residential 150200250300
Width Depth
300350400450500550600
Non - Residential400450500550600700800
200250300350400500600
Part 10 :
Table 6 : Dimensions of preferred sizes for reinforced concrete columns
150
200
250
300
350
400
450
500
550
600
650
700
750
800
Width Depth
150
200
250
300
350
400
450
500
550
600
650
700
750
800
Part 10 :
Table 7 : Dimensions of preferred sizes for reinforced concrete wall
Width Length
100
150
200
250
300
400
600
900
1200
1800
2400
3000
3600
4200
Part 10 :
Table 8 : Dimensions of preferred dimensions for reinforced concrete slabs
Thickness Length
100
125
150
175
200
600
900
1200
1800
2400
3000
3600
4200
Part 10 :
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MS 1064: 2018 (in progress)
2018 version of Part 10 has been published
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IBS Score
A systematic and structured assessment system
that can be used to measure the usage of IBS in
a consistent way.
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Parts of IBS Score
•Part 1: Structural Systems
•Part 2: Wall Systems
•Part 3: Other Simplified Const. Solutions
Structure
50+
Wall
20 +Others
30 = 100
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STRUCTURAL SYSTEM WALL SYSTEM
OTHER SIMPLIFIED CONSTRUCTION
SOLUTIONS
IBS Score Formula
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PRECAST CONCRETE
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
KONKRIT PRATUANG
Most popular IBS; IBS yang paling popular;
Local players familiar with
concrete; Penggiat tempatan biasa
dengan konkrit;
Relatively low manufacturing
set-up cost; Kos penyediaan tempat
pembuatan yang agak rendah;
On or off-site; Di tapak atau di luar tapak;
Produced using reusable
moulds; and Dihasilkan dengan
menggunakan acuan berulang;
dan Can produce various shapes
and designs; also std sizes Boleh dibuat pelbagai bentuk
dan rekabentuk; juga saiz std
Relatively low material cost; Kos bahan yang agak rendah;
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Columns Beams Hollow Core
Slabs
Non-Load Bearing
Wall
Load Bearing
Wall
Staircases
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Precast Concrete
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Sistem Kerangka
(Tiang, Rasuk & Papak)
Frame System
(Column, Beam & Slab)
Sistem Panel Dinding
(Dinding Galas Beban)
Wall Panel System
(Load bearing wall & slab)
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Jenis-jenis Sistem Struktur
Konkrit Pratuang
Types of Structural Systems in Precast Concrete Structures
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Precast Concrete Components of
Framed Buildings
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Komponen Pratuang Bangunan Kerangka
• Precast structure component• Komponen struktur pratuang
• Column• Tiang
• Beam• Rasuk
• Slab• Papak
• Staircase• Tangga
• Precast concrete connection• Penyambung konkrit pratuang
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Tiang Konkrit Pratuang
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Precast Concrete Column
• Tiang konkrit pratuang adalah elemen agihan utama beban menegak bagi struktur kerangka.
• Precast concrete columns are the main element of vertical load distribution for framed structures.
• Tiang konkrit pratuang juga boleh direkabentuk bagi merintangi daya ufuk bagi struktur yang direkabentuk sebagai ‘bukan dirembat’.
• Precast concrete columns can also be designed to resist horizontal forces for the structure designed as a 'unbraced'.
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Rasuk Konkrit Pratuang Precast Concrete Beam
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
• Rasuk konkrit pratuang adalah elemen utama mengagihkan beban secara mendatar.
• Precast concrete beams are the main elements that distribute loads horizontally.
• Rasuk konkrit pratuang boleh direkabentuk sebagai secara ‘simply-supported’ ataupun
secara ‘continuous’.
• Precast concrete beams can be designed as simply supported or continuous.
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Papak Konkrit Pratuang Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Papak konkrit pratuang mempunyai beberapa kelebihan:
Precast concrete slab has several advantages:
• Kualiti pembuatan yang lebih baik.
• Better manufactured quality.
• Boleh direkabentuk dengan mempunyai rentang yang lebih panjang seperti ‘hollow core slab’.
• Can be designed to have a longer span such as 'hollow core slab’
• Boleh digunapakai sebagai ‘permanent concrete formwork’.
• Can be used as a 'permanent concrete formwork'.
• Proses pemasangan tidak memerlukan sokongan perancah yang banyak.
• The installation process does not require a lot of support props / scaffolding.
• Kerja pemasangan yang pantas.
• Fast installation work.
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Papak Konkrit Pratuang Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Antara jenis papak konkrit pratuang adalah:
Types of precast floor slabs are:
• Hollow core Slab • Hollow core Slab
• Precast RC / Prestressed Slab • Precast RC / Prestressed Slab
• Precast Half Slab • Precast Half Slab
• Precast Single / Double Tee Slab
• Precast Single / Double Tee Slab
• Bubble Deck Slab • Bubble Deck Slab
• Precast Toilet Slab • Precast Toilet Slab
Papak konkrit pratuang dikilangkan berdimensi standard 1.2 m & 2.4 m lebar mengikut jenis papak yang digunakan.
Precast concrete slabs are manufactured to the standard dimensions of 1.2 m and 2.4 m in width according to the type of slab used.
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Papak Konkrit Pratuang | Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
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Papak Konkrit Pratuang | Precast Concrete Slab
Hollow-core Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
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Papak Konkrit Pratuang | Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Precast Prestressed Concrete
Solid Slab
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Papak Konkrit Pratuang | Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Precast Concrete Half Slab
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Composite Floor-Plates With Polystyrene
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Papak Konkrit Pratuang | Precast Concrete Slab
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Papak Konkrit Pratuang | Precast Concrete Slab
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Double Tee Slab
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Composite Floor-Plates With Plastic Balls (Bubbledeck / Cobiax)
Span Range: 6m-18m
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Papak Konkrit Pratuang | Precast Concrete Slab
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Dinding Galas Beban
Load Bearing Wall
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Dinding Konkrit Pratuang
Precast Concrete Wall
Dinding Tidak Galas Beban
Non Load Bearing Wall
Dinding Biasa |
Plain Wall
Dinding Ricih |
Shear Wall
Shaf Lif |
Lift Shaft
Dinding Berlapik |
Sandwich Wall
Dinding Berembat |
Braced Wall
Dinding Parapet |
Parapet Wall
Dinding Fasad |
Façade Wall
Dinding Konkrit Ringan |
Lightweight Concrete Wall
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Dinding Konkrit Pratuang Precast Concrete Wall
Pengena lan Rekabentuk IBS
I n t roduct ion to I BS Des ign
Dinding Konkrit Pratuang boleh direkabentuk mengikut keperluan struktur bangunan:
Precast concrete walls can be designed in accordance to the requirements of the building structure:
• Plain Wall
• Shear Wall
• Lift shaft Wall
• Plain Wall
• Shear Wall
• Lift shaft Wall
Dinding Konkrit Pratuang biasa direkabentuk dengan ketebalan 100mm hingga 300mm mengikut keperluan struktur.
Precast concrete walls are normally designed with thickness of100mm to 300mm in accordance to the structural requirements.
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General Guide
on
Moulds & Elements
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Minimise number of moulds
Different size of windows can easily be
changed during casting using one
standard mould
Symmetrical elements can be used on
both sides of buildings
Easier to add profiles, windows, holes to a
basic mould than to remove a part of a
finished mould
Design for largest practical size, weight &
dimension
Precast Concrete – Moulds &
Elements
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Check vehicle capacity
Check crane capacity, on and offsite
Architect to work closely with structural engineer in
concept design phase
Design components to be produced flat down with
the desired pattern, windows, cantilevers
incorporated at the bottom of mould
Sides of mould normally needed for demoulding
Precast Concrete – Moulds &
Elements
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The up-side of components will be flat and
finished by hand; roughened
Upstands have to be casted in a second operation
Design all 90 degree edged with min 6mm
chamfer to avoid chipping during
demoulding, transport, erection
Profiles, recesses, grooves must have angle of
at least 5 (smaller) to 10 degrees (larger items)
Precast Concrete – Moulds &
Elements
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When providing for windows and holes,
avoid dimensions less than 200 x 120 mm
Be aware that structural joints will be in-situ and
will have different surface type than the
precast finishes
Include gridlines on all design drawings and relate
all dimensions in the building to the gridlines
300mm horizontal planning grid relates to the
width of prefab slabs; as modular basis for the plan
Precast Concrete – Moulds &
Elements
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START
Mould Fabrication
Mould Set UpRebar
Arrangement
M&E Conduit Placement (if applicable)
Architectural & Cast In Item (if
applicable)
Mix / Order Concrete
Slump Test
A
Passed
Failed
Production Flow (Part 1 of 2)
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Further Test (ie; rebound hammer /
coring etc)
A
Concreting
Cube Test
*(fci > 15 Mpa)
Cured until achieve the
required strength
Lifting & Stacking
Cube Test
*(fci > 25 Mpa)
Installation
END
Cube Test
*(fcu > 40 Mpa)
Failed
Passed
PassedFailed
* Value of fci & fcu could varies based on design requirement
Dispacth to Site
Cured until achieve the
required strength
Failed
Production Flow (Part 2 of 2)
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Penyediaan Acuan – Alas Keluli & Acuan Sisi
Mould Set Up – Steel Bed & Side Moulds
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Pemasangan Tetulang keluli, Bingkai Tingkap & Pintu dan Konduit
Reinforcement Bar, Window & Door Frames and Conduit Installation
Tetulang keluli
Reinforcement
Bar
Bingkai Tingkap & Pintu
Windows & Door Frame
Konduit M&EM&E Conduit
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Pemeriksaan Kualiti – Semakan Pra-Penuangan Konkrit
Quality Inspection – Pre-concreting Check
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Manufacture, Production and Installation of Precast Concrete Components
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Penuangan konkrit
Concreting
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Penyingkiran dari acuan
Demoulding
Jalankan ujian kiub untuk memastikan yang kekuatan minima konkrit untuk mengangkat telah dicapai sebelum melakukan penyingkiran dari acuan
Carry out cube test to ensure minimum lifting strength of concrete is achieved before demoulding
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Pemeriksaan kualiti pada produk yang telah siap
Quality check on finished products
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Penyimpanan di kilang
Storage at factory
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Manufacture, Production and Installation of Precast Concrete Components
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Logistik
Logistics
Penghantaran ke tapakDelivery to site
Penghantaran Tepat-Pada-WaktuJust-In-Time (JIT) Delivery
Jenis kren ditetapkan oleh berat elemen, aksesibiliti di tapak dan jarak boom dan kapasiti pengangkat yang sepadan.
Type of crane depends on weight of element, site accessibility and boom length and its corresponding lifting capacity.
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Penyimpanan di tapak
Storing at site
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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1 Pasukan = 4 – 6 orang – Pengurangan pekerja di tapak1 Team = 4-6 Person - Reduced site labour
Pemasangan
Installation
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
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Training : Research : Publications : ICT SolutionsPemasangan Rasuk | Beam Installation
Pemasangan Tiang | Column Installation
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
Pemasangan: Sistem Kerangka PratuangInstallation: Precast Frame System
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Pemasangan Papak | Slab Installation
Pemasangan Panel Dinding | Wall Panel Installation
Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
Pemasangan: Sistem Kerangka PratuangInstallation: Precast Frame System
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Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
Pemasangan: Sistem Panel Dinding PratuangInstallation: Precast Wall Panel System
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Pembuatan, Pengeluaran dan Pemasangan Komponen Konkrit Pratuang
Manufacture, Production and Installation of Precast Concrete Components
Pemasangan: Tangga PratuangInstallation: Precast Staircase
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