IBS 101 - Innovacia Sdn Bhd

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Training : Research : Publications : ICT Solutions

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

http://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.

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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.

Download IBS 101 Slides

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Consultancy : Training : ICT Solutions : Publications


Smart applications that are relevant through

2025


Consultancy : Training : ICT Solutions : Publications




Lunt Fort, Coventry

AD 43 Prefab Roman Timber Forts

43




1579 Nonsuch House Holland to England

No nails

1624 Panelised Wooden Houses England to New England

1624




Late 1700s To Australia & South Africa

1833 Henry John Manning Portable Colonial Cottage

First documented house

1833




1851 Joseph Paxton's Crystal Palace

1851




1960 Danish Open System

1960




1968 BES – Finnish Open System

1968




1966: Pekeliling Flats

1969: Rifle Range Flats




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




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



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




Innovative Systems

Precast Concrete Blocks Steel Frames

Formwork SystemsTimber Frames


CIS 24 :

2018

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.



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




Expensive (?)Transportation

Precise MeasurementPractical Detailing

CoordinationTrained Workers

Plant Design / Production FlowEarly Planning

Changes




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



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)




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 :



MS 1064: 2018 (in progress)

2018 version of Part 10 has been published


IBS Score

Not based on volume

Not based on project cost

But based on a scoring system

IBS Score

A systematic and structured assessment system

that can be used to measure the usage of IBS in

a consistent way.



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




STRUCTURAL SYSTEM WALL SYSTEM

OTHER SIMPLIFIED CONSTRUCTION

SOLUTIONS

IBS Score Formula




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;




Columns Beams Hollow Core

Slabs

Non-Load Bearing

Wall

Load Bearing

Wall

Staircases




Precast Concrete




Sistem Kerangka

(Tiang, Rasuk & Papak)

Frame System

(Column, Beam & Slab)

Sistem Panel Dinding

(Dinding Galas Beban)

Wall Panel System

(Load bearing wall & slab)



Jenis-jenis Sistem Struktur

Konkrit Pratuang

Types of Structural Systems in Precast Concrete Structures




Precast Concrete Components of

Framed Buildings



Komponen Pratuang Bangunan Kerangka

• Precast structure component• Komponen struktur pratuang

• Column• Tiang

• Beam• Rasuk

• Slab• Papak

• Staircase• Tangga

• Precast concrete connection• Penyambung konkrit pratuang




Tiang Konkrit Pratuang



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'.




Rasuk Konkrit Pratuang Precast Concrete Beam



• 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.




Papak Konkrit Pratuang Precast Concrete Slab



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.




Papak Konkrit Pratuang Precast Concrete Slab



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.




Papak Konkrit Pratuang | Precast Concrete Slab







Hollow-core Slab









Precast Prestressed Concrete

Solid Slab







Precast Concrete Half Slab




Composite Floor-Plates With Polystyrene










Double Tee Slab




Composite Floor-Plates With Plastic Balls (Bubbledeck / Cobiax)

Span Range: 6m-18m







Dinding Galas Beban

Load Bearing Wall



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




Dinding Konkrit Pratuang Precast Concrete Wall



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.




General Guide

on

Moulds & Elements




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




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


Elements




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)


Elements




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


Elements




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)




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)




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




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






Pemeriksaan Kualiti – Semakan Pra-Penuangan Konkrit

Quality Inspection – Pre-concreting Check






Penuangan konkrit

Concreting






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






Pemeriksaan kualiti pada produk yang telah siap

Quality check on finished products






Penyimpanan di kilang

Storage at factory






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.






Penyimpanan di tapak

Storing at site






1 Pasukan = 4 – 6 orang – Pengurangan pekerja di tapak1 Team = 4-6 Person - Reduced site labour

Pemasangan

Installation





Training : Research : Publications : ICT SolutionsPemasangan Rasuk | Beam Installation

Pemasangan Tiang | Column Installation



Pemasangan: Sistem Kerangka PratuangInstallation: Precast Frame System




Pemasangan Papak | Slab Installation

Pemasangan Panel Dinding | Wall Panel Installation



Pemasangan: Sistem Kerangka PratuangInstallation: Precast Frame System






Pemasangan: Sistem Panel Dinding PratuangInstallation: Precast Wall Panel System






Pemasangan: Tangga PratuangInstallation: Precast Staircase




Thank you.

Contact us for your

IBS x BIM

solutions

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[email protected]@innovacia.com.my





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