B.tech Project 1 - Industrialised Building Systems
1. INDUSTRIALISED BUILDING SYSTEMS
Building Technology 1
Tutor : Mr Mohamed Rizal Mohamed
GROUP MEMBERS STUDENT ID
CARMEN CHAN SHEN WEN 0326485
CHAN JIA CHIN 0326560
CHAI PHEY CHIAT 0334480
CHRISTAL WONG CHING LING 0326715
KHOO SUE LING 0326470
2. 1. Concept and Framework of Selected IBS Category
1.1 Introduction to IBS System
1.2 IBS System
1.3 Case Studies
1.3.1 Introduction
1.3.2 Construction Process
1.3.3 Exploded Axonometric
1.3.4 Standard Size of Components
1.3.5 Standard Size of Components in Seri Jati Apartment
2. Architectural Drawings
2.1.1 Ground Floor Plan
2.1.2 First Floor Plan
2.1.3 Second Floor Plan
2.1.4 Roof Plan
2.1.5 North Elevation
2.1.6 South Elevation
2.1.7 East Elevation
2.1.8 West Elevation
2.1.9 Section X1
2.1.10 Section X2
2.1.11 Section X3
2.1.12 Section Y1
Construction Drawings
2.2.1 Foundation Layout Plan
2.2.2 Ground Floor Beam Layout Plan
2.2.3 First Floor Beam Layout Plan
2.2.4 Second Floor Beam Layout Plan
2.2.5 Roof Beam Layout Plan
2.2.6 Isometric
3. IBS Components
3.1 Apartment Design Features
3.2 Cast In Situ Pad Foundation
3.3 Precast Column
3.4 Precast Beam
3.5 Reinforced Precast Hollow Core Floor Slab
3.6 Precast Wall Panels
3.7 Precast Staircase
3.8 Roof - Steel Framing
4. Sequence of Construction
5. Schedule of Modular Components
6. IBS Score Calculation
7. Conclusion
8. Reference
TABLE OF CONTENTS
4. 1.1 INTRODUCTION TO IBS
Industrialised Building Systems (IBS) is a construction technique that uses components that
are manufactured in a controlled environment such as factories. In other countries, IBS is also
known as Prefabricated Construction, Off-site Construction and Modern Method of
Construction (MMC).
The components are produced in a modular manner in order to allow for industrialised mass
production.
There are two kinds of systems under IBS:
1. Open System refers to the standardisation of components that allows compatibility and
interchangeability among different manufacturers in any project.
2. Closed System refers to specific components that can only be used in specific
projects by certain manufacturers.
IBS started in Malaysia in the 1960s as an effort to increase quality while decrease cost,
manpower and construction time. The low-cost flats in Jalan Pekeliling are an example of
early IBS buildings in Malaysia. However, conventional construction methods still remained
vastly more popular than IBS.
From the 1990s, the government started to advocate and promote IBS by passing legislations
such as guidelines, regulations and circulars. Combined with the increased need for new
development, IBS has been increasing in popularity.
1.1.3 Types of IBS used in Malaysia
1. Precast Concrete System
Precast concrete components
are produced by casting
concrete in reusable formwork
in a factory. Components
available are columns, slabs,
walls, beams and components
such as stairs and balconies.
2. Blockwork System
Blockwork components are
concrete blocks that are able
to interlock and stack on
each other to create a
structure. Blockwork
components are load
bearing.
3. Formwork System
This system uses a series of
modular formwork for in-situ
concrete. Formworks can be
reused up to 80 times.
4. Steel Framing System
Steel frame components are
produced in a factory before
delivered to site for assembly. It
is widely used in factories and
large span structures where the
strength of steel are valued over
its high initial cost.
5. Timber System
Timber frame components
are produced in a factory off
site. Components available
are columns, beams, wall
frames and roof trusses. It is
popular due to its aesthetic
values.
6. Hybrid System
Hybrid systems use a
combination of 2 or more
IBS systems. This is to
utilise the advantages and
minimise the disadvantages
of different systems.
1.1.1 Advantages & Disadvantages of IBS
Advantages
- Cost effective
- Reduce manual labour needs
- Less wastage
- Increase productivity
- Increase quality
- Reduce safety risks
Disadvantages
- Expensive for small scale projects
- Require skilled experienced labour
- Decreased flexibility of design
- Improper planning could pose serious problems
- Require enough space for storage
1.1.2 IBS Workframe
1. Design &
planning
2. Fabrication of
components in
factory
3. Transportation
of components
4. Assembly of
components.
5. Installation
of finishes
5. Walls
1.2 PROPOSED IBS SYSTEM
Precast concrete systems are the most popular method of IBS construction in Malaysia.
Precast concrete components are produced by casting concrete in reusable formwork made
of steel or fibreglass in a controlled environment such as factories before transported to the
construction site for assembly and installation.
Precast concrete components are available as columns, beams, slabs, walls and 3D
components such as staircases, balconies, etc.
1.2.2 Example Types of Precast Concrete Components
Advantages
- Widely available due to its popularity
- Easy to install
- Does not need further insulation
- Reduces time & manual labour needs
- Wide variety of options for finishes (can be
left without finishes)
Disadvantages
- Require heavy duty vehicles for
transportation
- Require cranes for installation
- Large space for storage
- Transportation issues might lead to delays
1.2.1 Advantages & Disadvantages
SlabsColumns Beams 3D Components
Load Bearing - support structure
Infill - does not support structure
Number of corbels depends on the
number of beam connections
Prestressed - increased strength
which allows for longer spans
Conventional - ledge allows slabs
to rest on it (Spindel / ledgers)
Hollow Core - void in the centre to
reduce self-weight
Solid - minimise the depth of slab
Precast Stairs
Precast Refuse Chute
6. 1.3 CASE STUDY - Seri Jati Apartment, Setia Alam
The scoring point of this construction apartment is in the design. Its design features
elements in vertical and horizontal repetition. This contributed to the consistent quality.
According to the score, repetition in floor to floor height, vertical repetition and horizontal
repetition of structural floor layout are 83% respectively. The spatial configuration within a
singular unit consists of no columns and projected beams. Consistent squareness and
quality is maintained throughout the unit.
1.3.1 Introduction
Seri Jati is a 6 block Seri Jati residential apartments. It has 948 units in total with each apartment
block spanning 10 storeys in a single phase development.
The other scoring point is that it utilised precast structural frame with in-situ concrete floor using
Reusable Formwork System. The Reusable Formwork System is a temporary structure that can be
applied into the permanent structure. It reduces half the value of typical cast-in concrete, thus reducing
forming and construction cost. Due to the regular and repetitive features of the building, this type of
reusable formwork system is therefore suitable for this construction.
The way the residential apartment Seri Jati complies to the IBS Guidelines shows that the construction
planning has taken many considerations into account mainly to save cost. This includes planning of wall
layout, work sequencing, craneâs capacity and movement.
7. 1. Installation of Foundation 2. Installation of Precast Concrete Columns 3. In-Situ Ground Floor Slab
4. In-Situ First Floor Slab
5. Installation of Precast Components for First Floor 6. In-Situ Second Floor Slab 7. The construction process had been repeated until 10th floors
1.3.2 Construction Process:
8. 1.3.3 Exploded Axonometric
Prefabricated Steel Roof Trusses
Precast Walls for Roof
In-Situ Typical Floor Slabs
Precast Components:
âą Precast Load Bearing Wall
âą Precast Non-Bearing Walls
âą Precast Staircase & Landing Slabs
âą Precast Lift Core Walls
âą Precast Bathroom Slabs
âą Precast Air-Cond Ledges
Conventional Construction
âą Foundation
âą Ground Floor
âą Transfer Beam
âą RC Slab
1.3.4 Standard Size of Components
Sizes of the Components are made according to MS 1064:
Precast Concrete Column 150mm X 150mm Width
Precast Concrete Beam 150mm Width X 300mm Depth
Precast Concrete Wall 150mm Width X 900mm Length
Precast Concrete Slab 200mm Thk. X 4200mm Length
Prefabricated Steel Roof Trusses
9. Precast Concrete Column
150mm X 150mm Width Precast Concrete Wall 150mm Width
Precast Staircase 3000mm Height with
167mm Riser and 250mm Thread
Windows Size 1200mm Height with
1200mm Width
Standard Door Size 2100mm Height
with 900mm Width
1.3.5 Standard Size of Components in Seri Jati Apartment, Setia Alam
Standard Toilet Size
1500mm X 2800mm
Precast Lift Core Walls
30. 3.2 Cast in Situ Pad Foundation
Cast in Situ Pad Foundation is a type of foundation which is created on site, support point loads such as columns
and ground beams in this construction. To support a precast concrete structural frame, the pad foundation is
connected to the precast concrete columns by anchor bolting. Anchor bolts will transfer tension, compression and
shear forces to the base structure. To properly connect using this method, anchor bolts are drilled into the foundation
pads before connection with the columns. This is followed by the precast concrete columns which are connected to
column shoes, where it is made feasible for connection. This type of connection does not require bracing to be
reinforced.
Installation Procedure :
1. In the precast factory, foundation is drilled with anchor bolts.
2. Column is connected with column shoe.
3. Column is then connected to the anchor bolts in the pad footings.
3.1 Apartment Design Features
This apartment introduces design features. It is simple in simple geometrical design,
its rectangular grid is the optimal grid configuration. It is also repetitive in design. This
apartment also utilises structural precast skeletal frame, which comprises of columns
and beams with a precast floor system. The frame for this structural system is
moment resisting. This design has taken the IBS guidelines into consideration, hence
this influences the choices of the IBS components.
Repetitive Features
Rectangular Grid
Structural Precast Skeletal Frame
Suitability :
1. Versatile for simple connection, does not require complex connections which may cause
complications in the future
2. Fabricated and reinforced to resist up to high stresses during construction
3. Able to resist superior loads from structure
Connection Detail :
Fabrication Process :
1. Excavate small site for
pad foundation
2. Create formwork 3. Install starter bars 4. Pour concrete into
formwork as column
stump
Cast in Plate
Precast Column
Dry Pack
Screwed Anchor
Cast in Situ Foundation Pad
Shims
31. 3.3 Precast Column
Precast columns are manufactured as either multi-storeyed corbelled columns or
single floor-to-floor corbel elements. In this case, this construction utilises single
floor-to-floor corbel elements, because they are simple in design, detail and
constructed, complementing the repetition feature in this apartment design. For this
construction, initial column profiles and edge column profiles are implemented to
support walls.
3.4 Precast Beam
Precast beams are simple and practical in design. For this construction, the Spandrel - L shaped, and the
Ledger - inverted Tee profile are applied. They are designed to be continuous to improve further loads. The
precast floor components sit directly on the protruded ledge of the inverted Tee.
Installation Procedure :
1. To connect column to beam, the corbel of the column is applied in the
connection.
2. Weld column and beam using steel angles.
Installation Procedure :
1. Install U-shaped bars into precast beam.
2. Install continuous longitudinal bars at the top of precast beam.
Suitability :
1. Intentional manufacturing - maintain consistency in connection and bearing
of loads from other structural components, thus reducing construction cost
2. Already manufactured to be fire-rated
3. Versatile in variety of sizing and configuration (initial corbel column/edge
corbel column)
Suitability :
1. Like the precast columns, precast beams have high potential in producing highly consistent connections
and construction outcome.
2. Sturdy and dense character limits noise transfer from floor to floor - feasible for residential buildings such
as this
Fabrication Process :
Connection Detail :
Fabrication Process :
Connection Detail :
1. Insert rebar
cage that will act
as reinforcement.
Then, set up
formwork.
2. Secure formwork
with kickers as
bracing.
3. Pour concrete into
formwork. Then,
poker is used to
spread concrete
evenly.
4. Smoothen
concrete with slider.
1. Fix the beam
reinforcement.
2. Place the beam
cage into the mould.
3. Pour concrete into
the formwork.
Column of
top floor
Welded
steel
angle
Grout
Column of
bottom
floor
Initial
Column
Edge
Column
4. Smoothing the
concrete with slider.
(Details of precast beam connection by Cheng, 2016)
32. 3.5 Reinforced Precast Hollow Core Floor Slab
For this construction, hollow core slabs are used because it has an optimum span range,
its maximum span reaching a capacity of 2.4KN/sqm over a 16 metre span. This optimum
range is influenced by direct cost such as transportation, and also indirect cost during
erection and the method of connecting to the beams. These slabs are highly efficient. Due
to its optimised profiles, they are very versatile that they can achieve span to depth ratios,
unlike other floor types.Hollow core slabs are layered with a structural screed to tie the
structure together and help provide diaphragm action in the floor system. These slabs are
also capable in being reused and recycled at the end of its life cycle.
3.6 Precast Wall Panels
The precast walls built in this apartment is a face finish similar to a cast-in-place walls. These wall panels are
incorporated with door and window openings. The precast wall panels are designated with connection points,
which are important to support the structural load of the apartment. The types of precast walls used here are
load bearing walls which resist and transfer loads and shear walls which provide lateral load resistance.
Installation Procedure :
1. Secure bolt onto L-shaped bracket which is on wall panel.
Installation Procedure :
1. Grout the reinforcing bars on the slab keyways of the hollow core floor slab
2. Set hollow core floor slab on bearing pad
Suitability :
1. Precast hollow core slabs reduce in self slab weight, therefore maximising
structural stability.
2. Act as a barrier for sound and fire - ideal for residential units such as these
3. Require no drilling for electrical installation.
Fabrication Process :
Connection Detail :
Suitability :
1. Energy efficient due to its high thermal mass - helps prevent the building from getting too hot
2. Possess load bearing capabilities - act as a lateral stabiliser to support structural load from roofs and
wind
Fabrication Process :
Connection Detail :
1. Insert rebar cage. 2. Set drillers into the
framework in place to
create openings in
the slab.
3. Spread concrete
evenly
4. Smoothen concrete
using slider.
1. Assembly of
Wall Panel mould.
2. Fixing of Rebars. 3. Pouring concrete
into the mould.
4. Curing of concrete. 5. Demoulding.
Precast Hollow core
floor slab
Bearing Pad
Reinforcing bars
Precast concrete wall
Precast concrete wall
Bolt
33. 3.7 Precast Staircase
The type of precast staircase used is the arrangement which a complete flight with
number of steps required. This fabricated staircase include landings, support points
layered with sound insulation. They are a separate component away from the wall
panels.
3.8 Roof Steel Framing
Suitability :
1. Do not require fixing or propping during erection.
2. Highly flexible and accurate in the production process.
Fabrication Process :
Connection Detail :
Suitability :
1. Lightweight - reduce transportation cost
2. High resistance against weathering and insect infestations.
Fabrication Process :
Connection Detail :
The type of roof truss used in this construction is the howe type. In comparison to timber roof framing, steel roof
framing are more expensive, however they are more durable and require minimal maintenance. In comparison to
timber roof framing, steel roof framing do not require treatment to resist natural substance. The nature of steel
roof framing makes it environmentally conscious by being easily recyclable.
Installation Procedure :
1. Secure anchor bolt in in top of column.
2. Install sill plate on top of column.
3. Bolt roof truss to connect to sill plate.
Installation Procedure :
1. Cast rebate in precast floor slab
2. Install angle at edge of staircase and edge of rebate cast.
1. Insert reinforcing bars
into formwork.
2. Set up and reinforce
formwork.
3. Pour and poke
concrete to spread it
evenly.
4. Once cured and set,
lift made precast
staircase for
transportation.
1.Cut the steel into the
correct shape to start the
forming process.
2.Press and bake the
steel.
3. Welding the pieces
of steel together to
form the truss.
Connection for
top landing :
Rebate cast in
floor slab for
angle
connection
Connection for
bottom landing :
Rebate cast in
floor slab for angle
connection
(Connection detail of roof to column from Hilti, 2015)
Min 4 bars
(continuous)
Precast concrete
wall
Anchor bolt
Sill plate
Roof truss
35. 1.Installation of foundation pad
footings.
2. Installation of precast concrete
columns onto the pad footings.
3. Installation of ground floor slabs.
4. Installation of precast walls on ground
floor slabs. Some wall panels have been
cut to accommodate the opening sizes.
Next, the installation of prefabricated
windows and doors.
5. Installation of precast staircase. 7. Repeat sequence of installation
of columns, floor slabs, walls,
staircase, windows and doors for
1st and 2nd floor.
4.1 CONSTRUCTION PROCESS
36. 8. Roof structure is supported by the
repeating order of column and
beams. Prefabricated steel roof
trusses are placed above the column
and beams of 2nd floor.
10. Interior ceiling covering, wire
mesh, insulator and roof tiles were
then laid on site to complete the
building.
11. Finishing it up by exterior wall
paintings and interior tile finishings.
55. Overall, our 3-storey apartment has managed to reach a fully Industrialized Building System with
a score of 100% from the Ground Floor to the Roof. This is achieved through the use of all
Precast components adhering to standard dimensions of manufacture. The IBS Components
that was implemented are the precast columns, precast beams, precast hollow core slabs,
precast wall panels and prefabricated steel roof truss.
This project has familiarized us with the IBS method of construction and its advantages. IBS is a
very suitable method to be implemented in modern construction projects due to its efficiency. It is
time saving and requires less manpower. However, we learn that to produce an efficient IBS
based building, we should plan ahead on the details well that will assemble the building.
The project has increased our knowledge in all the IBS components through our research and
our opportunity to design an apartment. This project has also taught us that we can still be
creative and innovative with the use of mass produce components. The physical model also
gave us a hands on approach in experiencing the sequence of construction.
57. References
E-Books
Calculation for IBS Score. (2010). [Ebook] (pp. 1-7).
Precast Fabrication. [Ebook] (pp. 11-22).
Websites
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Experimental Study on Seismic Strengthening of Reinforced Concrete Frames by Precast Concrete Panels. (2011). ACI Structural Journal, 108(2).
Introduction to Steel Roof Trusses. (2019). Retrieved from http://mychina.biz/sh/index.php/en/90-tech-en/215-roof
Metric Concrete Industries. Retrieved from http://www.metric.com.my/content/hollow-core-slab.html
Modern Concrete Formwork Systems: Types, Reuse, Reliability & Risk Assessment. (2019). Retrieved from https://www.masterbuilder.co.in/modern-concrete-formwork-systems-types-reuse-reliability-risk-assessment/
Nasrullah, M. Retrieved from https://www.academia.edu/27033997/Precast_Concrete_-_Frames_Guide
OKA IBS CONCRETE PRODUCTS MALAYSIA. Retrieved from http://www.oka.com.my/index.asp?LanguagesID=1&TitleReferenceID=1216&CompanyID=29
Precast Concrete Column Beam Connections - New Images Beam. (2018). Retrieved from http://www.fotoimage.org/precast-concrete-column-beam-connections/
Therumahmurah.com. (2019). Selangorku Jade Hills 42k 100k 220k 250k (Type A,B,C,D). [online] Available at: http://therumahmurah.com/project-detail-selangorku-jade-hills-42k-100k-220k-250k-type-a-b-c-d-.php [Accessed 16 May 2019].