CHAPTER 2

INDUSTRIALISED BUILDING SYSTEM

2.0 INTRODUCTION

This chapter will explain in details and provide the literature review of Industrialised
Building System (IBS). This chapter will also cover the literature review of building
systems itself. Generally, the contents of this chapter are; definitions, history, types,
benefits, classification, characteristic, advantages, disadvantages, Open Building
System, Modular Coordination, implementation of IBS in Malaysia as well as its
barriers, IBS scoring system and IBS Roadmap 2003-2010.

2.1 DEFINITIONS OF INDUSTRIALISED BUILDING SYSTEM

Until the present time there has been no single commonly-approved definition of IBS.
IBS can be different things to different industry players. However, there are several
definitions from difference resources that reflected the concept of IBS which widely
accepted by the construction industry.

For the purpose of this research, IBS is best defined according to CIDB Malaysia
(2001). CIDB Malaysia (2001) defines IBS as 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. As such,
components that are being pre-fabricated in a controlled environment on-site are also
considered as IBS. While there are numerous descriptions of the Industrialised Building
Systems (IBS) concept by local researchers, all of the definitions stressed on pre-
fabrication and mass production.
According to 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. Industrialisation process is an investment in equipment, facilities and
technology with the objective of maximising production output, minimizing labour
resource and improving quality while a building system is defined as a set 10 of
interconnected element that joint together to enable the designated performance of a
building.

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. Another definition of IBS in the construction industry
includes the industrialized process by which components of building are conceived,
planning, fabricated, transported and erected on site (Thanoon & others (2), 2003).

Meanwhile, elaboration of IBS was also clarified by Junid (1986) 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 IBS to expand.

In early literature, Dietz (1971) defined IBS as a total integration of all subsystem and
components into overall process fully utilizing industrialised production, transportation
and assembly techniques.
Parid (1997) defined IBS as a system which use industrialised production technique
either in the production of component or assembly of the building or both.. According
to Trikha (1999), industrialised building system is a building system in which all
building components such as wall, floor, slab, beam and staircase are mass produced
either in factory or at site under strict quality control and minimal on site activities.

Lessing et al (2005) explained IBS as an integrated manufacturing and construction

process with well planned organization for efficient management, preparation and
control over resources used, activities and results supported by the used of highly
developed components.

Rahman et al (2006) defined IBS as a construction system that is built using pre-
fabricated components. The manufacturing of the components is systematically done
using machine, formworks and other forms of mechanical equipment. The components
are manufactured offsite and once completed will be delivered to construction sites for
assembly and erection.

IBS also can be defined as construction systems in which components are manufactured
in a factory, on or off site, positioned and assembled into a structure with minimal
additional site works (IBS Survey, 2003). The word ‘building’ in the IBS term relates to
‘constructing’ and therefore covers all type of structures (not only for buildings
construction). It is a products, system and techniques used in making construction less
labor-oriented, faster than and as well as quality controlled.

Furthermore, the word ‘prefabrication’ also frequent used while define Industrialised
Building System which carried the means “the manufacture of component parts of a
building and its services prior to their assembly on site” (Wilson, Smith and Deal,
1998). Prefabricated techniques can be used in a wide range of application during the
construction process, from the simple prefabricated site hut, up to volumetric units that
are designed for integrating into the building structure.
Beside, the term “Industrialised Building System” can be separate to several phases
which carried its own definition:

(i) ‘Industrialised system’ means to build on-site with elements or components

produced by series in plants. These components are things like floors, walls, column,
beams, and roofs. They are then assembled and erected on the site properly joined to
form the final units. (CIDB, 2001)

(ii) ‘Industrialised building’ is the term given to building technology where modern
systematized methods of design, production planning and control as well as mechanized
and automated manufacture are applied (Ingemar Lofgren and Kent Gylltoft, 2000).

(iii) ‘Building system’ means a building system includes design rules and a product
system whose parts have compatible interfaces, thus permitting the use of several
alternative components and assemblies. The compatibility of the components and
assemblies is assured by means of a dimensional and tolerance system as well as
connection and joints (Ingemar Lofgren and Kent Gylltoft, 2000).

Perhaps the most comprehensive definition of IBS is IBS in the construction industry
includes the industrialised process by which components of a building are manufactured
transported and erected on site and managed to produce lean construction. The system
includes a balanced combination between the software and hardware components. The
hardware elements are categorised into three major groups which includes frame
system, panel system, and box or modules system. Meanwhile the software elements
include system design, market analysis, development of standardised components,
establishment of manufacturing and assembly layout and process, allocation of
resources and materials and definition of a building designer conceptual framework.

2.2 CLASSIFICATION OF BUILDING SYSTEM

There are four types of building system in Malaysia according to Badir- Razali
building system classification. (Badir et al. 1998). The building systems are namely
conventional column-beam-slab frame system with timber and plywood as formwork,
cast in-situ system with steel or aluminium as formwork, prefabricated system and the
composite building system is shown in Figure 2.0. Each building system is represented
by its construction technology, functional and geometrical configuration. There from
the four systems, excluding conventional building system, are identified as
industrialised building system.

Building
System

Conventional Cast in-situ Prefabricated Composite

Column-Beam System with System Building
–Slab Frame Steel or
System with Aluminium as
Timber and Formwork
Plywood as
Formwork

Figure 2.0: Types of building system in Malaysia (Badir et al. 1998)

2.2.1 Conventional Construction Method

Badir et al, (1998) stated that conventional building method is defined as

components of the building that are prefabricated on site through the processes of
timber or plywood formwork installation, steel reinforcement, and cast in-situ.
Conventional buildings are mostly built of reinforced concrete frames. The traditional
construction method uses wooden formwork. It is much more costly for construction
which includes labour, raw material, transportation and low speed of construction time.

2.2.2 Cast-In-Situ Construction Method

According to Badir et al, (1998), this system is suitable for a country where
unskilled labour is limited. There is no heavy machinery or high technology involved.
The system is technically applicable to almost all types of building. Formwork is used
as a mould where wet concrete is poured into a temporary system. The temporary
system also acts as a temporary support for the structures.
The objective of an in-situ method is to eliminate and reduce the traditional site-
based trades like traditional timber formwork, brickwork, plastering and to reduce
labour content. A carefully planned in-situ work can maximise the productivity, speed
and accuracy of pre-fabricated construction. Cast in-situ method uses lightweight pre-
fabricated formwork made of steel/fiberglass/aluminium that is easily erected and
dismantled. The steel reinforcement is placed within the formwork as they are being
erected and concrete is poured into the mould. When the concrete is set according to the
required strength, the moulds are dismantled. The workers can be easily trained to erect
the moulds and set the steel reinforcement. Its advantages over the traditional
construction method include, low skill requirement, speedy construction, low
maintenance, durable structure and less cost.

2.2.3 Composite Construction Method

Badir et al, (1998) stated that the objectives of composite construction method
(partially pre-fabricated) are to improve quality, reduce cost, and shorten construction
time. The concept of partial industrialised system is derived from the composite nature
of full industrialisation, and is used to describe a manufacturing or production strategy
that selectively uses some industrialising aspects, while avoiding or postponing the use
of others. The pre-fabricated construction method is combined in such a manner that the
features applied could be prominently demonstrated, especially composing various
works such as temporary facilities, building frames, building finishes, and equipments.

2.2.4 Fully Pre-fabricated Construction Method

In this method of construction, all elements that can be standardised are pre
fabricated in the factory. Normally, this method would involve the assembly of precast
elements such as floor slabs, in-filled walls, bathrooms, staircases, etc. into place for
incorporation into the main units, columns and beams. This method of construction has
reduced the amount of site labour involved in building operations and increased the
 productivity of the industry. Precast building systems can reduce the duration of a
project if certain conditions are met. The last three construction methods are considered
as non conventional construction methods. These types of construction are specifically
aimed at increasing productivity and quality of work through the use of better
construction machinery, equipment, technology and materials.

2.3 CLASSIFICATION OF INDUSTRIALISED BUILDING SYSTEM

According to Badir et al. (1998), IBS can be classified according to several aspects;
i) Classification according to structural system
ii) Classification according to material
iii) Classification according to relative weight of components

2.3.1 Classification according to structural system

According to Abraham Warszawski (1999), IBS system can be classified according

structural systematic aspects. IBS can be classifies into three categories as:
• Linear system or frames (beams and column)
• Panel System
• Rectangular or Boxes system or Three dimensional system
Figure 2.1, Figure 2.2 and Figure 2.3 shows the concept of the system as classified
above.

2.1: Frame
Figure 2.2: SystemFigure 2.3: Box System
Panel System
2.3.1.1 Frame system

Frame system is system that use column and beam as the main structure member
where columns and beams support all the building weight. The walls need to be light
and easy to install and concrete panels are introduces as flooring element (Badir et al.,
1998).

2.3.1.2 Panel system

In panel system, loads are distributed through large floor and wall panels where
walls support the building weight. This system is applicable to buildings which
functionally require a large number of walls such as apartment house, hotel and
hospital. This system is not applicable to buildings with large spans or many stories
(Badir et al., 1998).

2.3.1.3 Box system

The box systems include 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 (Badir et al., 1998).
2.3.2 Classification according to material

i) Timber
There are two types of prefabrication of timber which is ready-cut plus shop fabrication
of joints (column and beam) and structural panels where there are only walls and floors
without column and beam.

ii) Brick and block work

Laying of brick or block are carried out in a mass at factory and transported to site or on
site beside the building under construction in the form of panel and then erected.

iii) Steel
Steel construction essentially contains factors of prefabrication which is one of the
criteria of IBS. Elements are jointed by welding, riveting or bolting on site. The large
proportion of the strength to the weight allows a long-span or high-rise building.
iv) Reinforced concrete
Reinforced concrete has high degree of availability, low material cost, durability, and
fire resistance. There are two basic directions in development of reinforced concrete

No General System Production Material

System
1 Frame Light weight frame Wood, light gage metals
System
Medium light weight frame Metal, reinforced plastics,
laminated wood
Heavy weight frame Heavy steel, concrete
2 Panel Light and medium weight Wood frame, metal frame
system panel and composite material
Heavy weight panel Concrete
(factory produced)
Heavy weight panel
Concrete
(tilt up-produced on site)
3 Box system Medium weight box Wood frame, light gage
(modules) (mobile) metal, composite
Medium weight box Wood frame, light gage
(sectional) metal, composite
Heavy weight box Concrete
(factory produced)
Heavy box Concrete
(tunnel produced on site)
IBS component which is panelised components such as walls and floors and precast
frame members such as columns and beams. Jointing at site is the key issue of this
system.

2.3.3 Classification according to relative weight of components

The IBS components can be classified according to their relative weight as in Table 2.4.
Majzub (1977) mentioned that the relative weight of components should be used as a
basis for building classification due to the factor of weight has significant impact on the
transportability of components and has influence on the production method of the
components and their erection method on site.
Table 2.4: Building system classification according to relative weight of component.
(Majzub, 1977)

According to CIDB (2001), the Industrialised Building System is a construction

process that utilizes techniques, products, components, or building systems which
involve prefabricated components and on site installation. Base on the structural aspects
of the system, IBS can be identified into five major groups:

i. Precast Concrete Framing, Panel and Box Systems

Precast concrete elements are the most common IBS type. There are precast concrete
columns, beams, slabs, walls, lightweight precast concrete, and permanent concrete
formworks. Beside, it is also consist of 3D components such as balconies, staircases,
toilets, lift chamber, refuse chambers and etc.
ii. Steel Formwork Systems

They generally involve site casting, and therefore subjected to structural quality control.
So, it is considered as the “low level” or the “least prefabrication” IBS types. However,
this system does offer high quality finishes and fast construction with less site labor and
material requirement. These include tunnel forms, tilt-up systems, beam and columns
moulding forms and permanent steel formworks like metal decks.

iii. Steel Framing Systems

This system commonly used with precast concrete slabs, steel columns and beams have
always been the popular choice and used extensively in the fast-track construction of
skyscrapers. Recent development in this type of IBS includes the increased usage of
light steel trusses. It is consisting of cost-effective profiled cold-formed channels and
steel portal frame systems as alternatives to the heavier traditional hot-rolled sections.

iv. Timber Framing Systems

The products are including timber building frame and timber roof truss. While timber
roof truss systems are more popular, timber building frame systems also have its own
niche market where it is offering interesting designs from simple dwelling units to
buildings requiring high aesthetical values such as chalets for resorts.

v. Blockwork Systems

By using this effective alternative system, the tedious and time-consuming traditional
brick laying tasks are greatly simplified. The construction method of using conventional
bricks has been revolutionized by the development and usage of interlocking concrete
masonry units (CMU) and lightweight concrete blocks.

2.4 CHARACTERISTICS OF INDUSTRIALISED BUILDING SYSTEM

The main features of an industrialised building system are as follows: (Warszawski,

1999).
i. As many of the building elements are prefabricated offsite, at a central facility,
where specialized equipment and organization can be established for this
purpose.
ii. The various building works are incorporated into large prefabricated assemblies
with minimum erection, jointing and finishing work onsite.
iii. Materials and component handling onsite is extensively mechanized; in concrete
work, large standard steel forms, ready-mixed concrete, and concrete pumps are
used.
iv. Design, production, and erection onsite are strongly interrelated. They must be
viewed therefore as parts of an integrated process which has to be planned and
coordinated accordingly.
Industrialised Building System has its own characteristics which are differ itself from
conventional method. There characteristics of Industrialized Building System are
(CIDB, 2001):
i. Industrial production of components though prefabrication; or highly
mechanized in-situ processes
ii. Reduced labor during prefabrication of components and site works.
iii. Modern design and manufacturing methods which has the involvement of
Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).
iv. Systematic Quality Control such as ISO 9000 principles.
v. Open Building concept where it is permitting hybrid applications, adaptable to
standardization and Modular Coordination (MC).

2.6 ADVANTAGES OF INDUSTRIALISED BUILDING SYSTEM (IBS)

According to CIDB (2003), compares to conventional construction method, the

industrialised building system has the following advantages:

i. Less construction time

IBS requires less construction time because casting of precast element at factory
and 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.

ii. Cost savings

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

iii. Saving in labour

When the IBS components are produced in factory, higher degree of utilisation of
machine is permitted and the use of labour will be reduced and lead to saving in
labour cost.
iv. Less labour at site
The use of IBS will reduce the construction process at site and consequently reduce
the number of labour required at site.

v. Optimised use of material

The utilisation of machine during the production of IBS components lead to
higher degree of precision and accuracy in the production and consequently
reduce material wastage.

vi. Higher quality and better finishes

An IBS component have higher quality and better finishes due to the careful
selection of materials, use of advanced technology, better and strict quality
assurance control since production in factory is under sheltered environment.

vii. Construction operation 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.

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

ix. Increase site safety and neatness

Utilisation of IBS components leads to less construction process especially wet
work at site. This will lead to the neater site condition and increase safety.

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

2.7 DISADVANTAGES OF IBS

Nothing in this world is perfect, so as industrialised building system. Disadvantages of

IBS are as follows:

i.High 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.

ii.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 through out the
year.

iii.Sophisticated plants and skilled operators

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.

iv.Site accessibility
 Site accessibility is one of the most important factors of the implementation of IBS.
IBS requires adequate sit accessibility to transport IBS components from factory to
the site.

v.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 sites especially in cities are often congested and unable to provide the
area required.

2.8 OPEN BUILDING SYSTEMS

The utilisation of IBS has made the concept of open building possible. Open
building system is a system that focuses on the need of the user. The concept of Open
Building is best captured by John Habraken's quotes:
We should not to forecast what will happen, but try to make provisions for the
unforeseen (John Habraken, 1961).
In the past, the dream of “living to your liking” is only affordable for those who
can spend a lot of money on their dwellings. Now, by using IBS, this dream is
affordable by almost everybody. Open building system separates a dwelling's utilities
from structural and enclosure systems, in which utility networks typically are
interwoven and buried, thereby liberating the floor plan.
Hence, interior partitions can be eliminated, modified or added easily, and this
allow existing rooms to be expanded, shrunk, merged, or reshaped. This system also
eases replacing or relocating plumbing and electrical fixtures, rewiring, and relocating
ducts and pipes.

2.9 MODULAR CO-ORDINATION

The concept of modular co-ordination was identified as an aid to the utilisation

of industrialised building system. In 1972, the decision to replace the existing imperial
system with the metric system has been made by government. This has lead to the
introduction of modular co-ordination in April 1986. The main reason of the change is
to provide an opportunity for technological advancement and rationalization in building
industry.
According to International Organization for Standard (ISO), the basic principle
of modular co-ordination is 1M = 100mm and this applied on the IBS components.
Trikha (1999) mentioned that modular co-ordination is a co-ordinated unified system
for dimensioning spaces, components, fitting, etc. so that all elements fit together
without cutting or extending even when the components and fittings are manufactured
by different suppliers.
Warszawski (1999) has mentioned two objectives of modular co-ordination. The
first objective is to create a basis for building components to minimize the variety of
types and sizes of building components. Each component is designed to be
interchangeable with other similar ones and hence the designer will have the freedom to
choose which components to use. The second objective of modular co-ordination is to
increase the adoptability of prefabricated components to any layout and their
interchangeability within the building.

2.10 IBS ROADMAP 2003-2010

A fundamental plan that involves all the important aspects is needed in

Malaysian construction industry to evaluate its process. In this respect, the IBS
Roadmap 2003-2010 is formulated as a reference for all parties in implementing all
programs towards the modernization of the Malaysian construction sector.
In year 2003, CIDB has produced IBS Roadmap 2003-2010 as the blueprint
document to be a reference point for the implementation of programmes by all parties
towards industrialising the construction sector. The IBS Roadmap’s main objectives
are:

i. Gradually reduces the percentage of foreign workers from the current 75% to
55% in 2005, 25% in 2007 and 15% in 2009.
 ii. Utilisation of IBS for 30% of total Government (Building Projects) gradually
increasing to 50% in 2006 and 70% in 2008.
iii. Towards reaching Open Building system and full industrialization by 2010.
iv. Among main strategies outlined in IBS Roadmap 2003-2010 are:
i) Reduce percentage of foreign workers especially those involved in
wet trades.
ii) Utilisation of modular co-ordination (MC) based on MS 1064
through Undang-undang Kecil Bangunan Seragam (UKBS).
iii) Utilisation of IBS for affordable homes.
iv) Utilisation of IBS in government projects (building).
v) Utilise approved IBS components only
vi) Reduce levy by CIDB for the utilisation of MC.
vii) Green-lane approval of building plans for plans using standard plan
designed according to MC and standard building components.
viii) Training scheme and loan to produce bumiputra IBS producer and
installer.
v. Budget 2005 also reveals that the usage of IBS components in government
building projects will be increased from 30 percent to 50 percent commencing
2005 and housing developers who utilise IBS components exceeding 50 percent,
will be given full exemption on levy imposed by CIDB.

Based on the IBS Roadmap 2003-2010, positive impacts from the fundamental proposal
and new government incentives are:

(i) The industry will choose IBS which guarantees better quality, productivity and
safety.

(ii) The enforcement of using Modular Coordination (MC) through Uniform Building
By Laws (UBBL) will encourage standardization and subsequently increase the usage
of IBS components. It also encourages participation from manufacturers and
assemblers, especially Bumiputera, to enter the market, thus reducing the price of IBS
components. MC will facilitate open industrialization.

(iii) A screening and selection program based in IBS standard components will ensure
that low quality products are not marketed in the country and this prevents the dumping
of foreign IBS products in Malaysia. This aspect is important to avoid failures in IBS
projects

(iv) By reducing wet-trades through IBS, the dependency on foreign workers will also
diminish, thus gaining the billions of Ringgit currently being transferred out by the
foreign workers to their home countries and reducing inherent social problems
involving these foreign workers.

2.11 IBS CONTENT SCORING SYSTEM (IBS SCORE)

As regulatory requirements such as “minimum percentage of utilisation of IBS in

government building projects” and encouragements such as “CIDB Levy exemptions
for a minimum percentage IBS utilisation” have been put forward, a system for IBS
content assessment is needed.
The IBS Content Scoring System (IBS Score) is a systematic and structured assessment
system that can be used to measure the usage of Industrialised Building Systems (IBS)
in a consistent way. The IBS Scoring System emphasizes on the following attributes:

i) The use of prefabricated and precast components

ii) Off-site production of components
iii) The use standardized components
iv) Repeatability
v) Design using Modular Coordination concept

Higher IBS Score is a reflection of a more reduction of site labour, lower wastage, less
site materials, cleaner environment, better quality, neater and safer construction sites,
faster project completion as well as lower total construction costs. The detail
information about IBS Score, methods of calculating IBS Score as well as sample
calculation are included in Manual for IBS Content Scoring System (IBS Score)
published by CIDB.

2.12 BARRIERS TO THE ADOPTION OF IBS IN MALAYSIA

A survey undertaken by CIDB in 2003 found that only mere 15% used IBS in the local
construction industry. According to Waleed A.M. Thanoon et al. (2003) the reasons of
slow adoption of IBS in Malaysia are:

i) Inconsistent of houses demand, high interest rate and cheap labour cost make it hard
to justify large capital investment and it is easier to lay off workers during slack period.

ii) A high degree of precision is required in fully prefabricated construction system

while Malaysia still lack of skilled workers.

iii) Too many parties involve in construction industries. The owners, contractors and
engineers still lack of scientific information about the economic benefits of IBS. This
make the agreement on the utilisation of IBS during planning stage difficult to be
achieved.

iv) Majorities of IBS in Malaysia are imported from developed countries and thus drive
up the cost.

v) The economic benefits of IBS are not well documented in Malaysia.

vi) Most projects constructed with IBS in Malaysia were low quality and high
construction cost. Utilisation of IBS in Japan and Sweden are so successful due to
projects constructed with IBS are high quality and high productivity.
vii) Many architects and engineers still unaware of the basis element of IBS such as
modular co-ordination.

CONCLUSION

There are many types of IBS existing in Malaysia: formwork precast load
bearing wall panel, precast frame, precast floor and hollow core slab, sandwich panel,
block panel, and steel frame. These IBS represent most of the IBS that exist worldwide.
Quality, speed of construction, and cost savings are the main advantages of these
systems. These factors are very important in implementing the Ninth Malaysia Plan.
The main disadvantages of the IBS in Malaysia are that they are highly capital intensive
and there is a need for experts at the construction site for some of them. The main
reason to recommend the use of IBS in Malaysia is that the raw materials used in the
IBS have to be produced locally in order to overcome the shortages that are being faced
by the IBS construction industry.