Penerbitan Majalah Promosi / Sistem Binaan Berindustri (IBS) • Julai – September 2005 • ISBN 983-2724-29-5

IBSDIGEST

Prefabricated Steel Buildings Provide an Economical Construction Alternative

Precast Installation PROCEDURESREALISING THE INDUSTRIALISATION OF MALAYSIAN CONSTRUCTION INDUSTRY:

CONSTRUCTION IT PERSPECTIVE

IBS A SHORT HISTORY Soalan-soalan

Yang Seringkali Ditanya (FAQs) Mengenai Sistem Binaan Berindustri (IBS) dan Kordinasi Modular (MC)

Program Promosi IBS WILAYAH SABAH

KANDUNGAN

Dari Meja Pengarang 1

Prefabricated Steel Buildings Provide an Economical Construction Alternative 2

Precast Installation Procedures 3

Realising The Industrialisation Of Malaysian Construction Industry: Construction IT Perspective 6

IBS A Short History 7

Soalan-soalan Yang Seringkali Ditanya (FAQs) Mengenai Sistem Binaan Berindustri (IBS) dan Kordinasi Modular (MC) 9

Program Promosi IBS Wilayah Sabah 11

Promosi IBS Wilayah Sarawak 12

Kompleks Sukan Nasional adalah binaan yang paling menyerlah di Kompleks Sukan Nasional Bukit Jalil. Laluan masuknya diperindahkan dengan arca keris sebagai lambang keperkasaan. Didirikan sebagai stadium untuk pelbagai acara, Kompleks Sukan ini menjadi lokasi untuk penganjuran pelbagai acara atletik, perlawanan bola sepak, pembukaan rasmi serta pelbagai acara bersejarah. Kompleks ini yang terletak 20km dari bandaraya Kuala Lumpur ini telah berjaya disiapkan oleh United Engineers tiga bulan lebih awal dari jadual.

Kompleks Sukan Nasional Bukit Jalil berjaya disiapkan pada tahun 1998 untuk Sukan Komanwel Kuala Lumpur. Struktur yang paling menyerlah di Kompleks Sukan ini, Stadium Nasional; adalah salah sebuah gelanggang sukan pelbagai acara yang terbesar dan paling moden di dunia. Kebanyakan komponen stadium dengan kapasiti 80,000 tempat duduk ini telah dibina menggunakan kaedah pembinaan IBS. Ini termasuk struktur bumbung keluli. breaches konkrit pratuang dan fasad berseni bina serta rangka keluli yang merupakan struktur utamanya. Beberapa struktur IBS lain yang terletak berhampiran kompleks ini termasuk Perkampungan Sukan Komanwel, Komanwel Vista, stadium tertutup dan stadium hoki menggunakan pembinaan hybrid in-situ dan pratuang

A quarterly promotional publication on Industrialised Building Systems • July – September 2005 • ISBN 983-2724-29-5

IBSDIGEST

PenasihatDatuk Ir. Hamzah HasanMegat Kamil Azmi Megat Rus Kamarani

Kami mengalu-alukan komen, artikel dan sebarang bentuk pengiklanan daripada pembaca. Sila hubungi:

Kumpulan Pengarang:

Ir. Elias IsmailIr. Shahrul Nizar ShaariRofizlan AhmadRozaiman HassanSyurhawati Abdul Rahim

Unit Pembangunan Teknologi, Bahagian Pembangunan TeknologiCIDB MalaysiaTgkt. 8, Grand Seasons AvenueNo. 72, Jalan Pahang, 53000 Kuala Lumpur

Tel: 603-26170200Faks: 603-40451808e-mel: tech@cidb.gov.my, ibs@cidb.gov.myLaman Web: www.cidb.gov.my

Walaupun pasaran dalam negara me-nyediakan peluang kerja yang terhad sekalipun, namun dengan daya saing yang tinggi melalui penggunaan IBS, perkhidmatan pembinaan negara masih boleh dipasarkan ke pasaran antara-bangsa yang banyak menyediakan pelu-ang perniagaan pembinaan. Isu IBS Digest keluaran ini memberi tumpuan kepada Pre-Engineered Build-ings (PEB), yang seringkali dirujuk seb-agai proses binaan pre-fabrikasi atau bi-naan keluli pre-fab iaitu kaedah pembi-naan yang digunakan secara meluas di Amerika Syarikat serta beberapa buah negara maju yang lain. Ia merangkumi satu sistem binaan berangka keluli den-gan komponen yang telah direkabentuk terlebih dahulu yang mudah dimuatkan ke dalam pelbagai kombinasi yang luas untuk memenuhi keperluan penggu-naan akhir khusus yang unik. PEB amat sesuai digunakan bagi pemasangan tetap. Antara kelebihan PEB berband-ing pembinaan keluli konvensional termasuk: penjimatan kos hasil kerja kejuruteraan yang dijalankan di kilang – PEB boleh mencapai sehingga 40% penjimatan kos berbanding pembinaan

secara konvensional; memerlukan asas yang lebih mudah; lekapan (seperti pin-tu dan tingkap) mengikut standard yang mudah dan cepat ditukar; pengurangan tempoh siap pembinaan – lazimnya bangunan boleh dibina hanya dalam tempoh beberapa minggu sahaja; proses pemasangannya boleh dilakukan dengan cepat dan cekap – boleh menji-matkan kos sehingga 20% berbanding penggunaan keluli konvensional; reka-bentuk secara modular – struktur PEB boleh diubah dan diperbesarkan dengan cepat dan mudah apabila diperlukan. Oleh kerana IBS merupakan kaedah pembinaan yang menjanjikan peny-iapan yang lebih cepat, menjimatkan kos, menjamin kualiti binaan, tahap keselamatan yang lebih tinggi, tidak memerlukan tenaga kerja yang ramai dan pelbagai manfaat lain; dalam jang-kamasa panjang, walaupun kos untuk menggunakan kaedah ini mungkin me-merlukan pelaburan permulaan yang agak tinggi sedikit, tetapi kos pelaburan tambahan ini mampu memberi pulan-gan yang menguntungkan. Oleh itu, beralihlah daripada kaedah pembinaan konvensional kepada kaedah Pembi-naan Secara Berindustri.

DariMeja Pengarang

ISSUE • JULY – SEPTEMBER 2005

IBSDIGEST 1

Banyak faktor menyumbang kepada kelembapan prestasi industri pembinaan masakini. Salah satu daripadanya ialah kekurangan tahap daya saing yang cukup teguh untuk bersaing di pasaran yang semakin hebat persaingannya. Penggunaan teknologi pembinaan; misalnya melalui penggunaan Sistem Pembinaan Berindustri (IBS), seseorang kontraktor boleh mendahului pesaingnya di pasaran dalam negara. Penggunaan IBS membolehkan kualiti, produktiviti, keberkesanan dari segi kos, keselamatan, ketepatan tarikh penyiapan dan kepuasan pelanggan mencapai tahap yang jauh lebih tinggi berbanding pembinaan secara konvensional.

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2 IBSDIGEST

Prefabricated Steel Buildings Provide an Economical Construction Alternative

Prefabricated Steel Building Background

The 20th century marked the beginning of the steel building industry. With the widespread use of automobiles in the early 1900s, one of the first uses of steel building was the garage. As consum-ers saw the low cost and value of steel, storage facilities, garages and storage sheds made of galvanized steel quickly spread around the country. In the first decade of the 1900s innovative build-ers also created farm storage buildings and grain bins out of steel instead of wood. By the end of the Depression, these storage bins had proven their du-rability when compared to wood struc-tures. This was validated in 1938, when the U.S. Department of Agriculture or-dered 30,666 steel grain bins to store surplus crops. This order amounted to 1 ½ times the number of steel grain bins created by the entire industry only one year before. In 1940 Butler Manufacturing Com-pany introduced the first line of prefab-ricated steel buildings using rigid frame design. (A rigid frame is a skeleton for the building’s framework, made of steel girders.) This allowed businesses to purchase larger and more capable steel buildings at a lower cost and with

a shorter construction schedule. By this time, the aeronautical world had em-braced steel as well; steel aircraft han-gars were being widely used in the civil-ian and military sectors. Following World War II, engineers continued to improve prefabricated steel buildings, increasing the size and sophistication of these building “kits.” The Metal Building Manufacturers As-sociation (MBMA) was founded in 1956 to drive innovation, standardization, and greater acceptance of prefabri-cated steel buildings. Their efforts have worked; the MBMA estimates that steel building systems were used for about $1 million of new construction in 1960. In 2000, steel building systems accounted for almost 1.16 billion square feet and $2.5 billion of new low-rise commercial construction.

Steel Building Advantages

One reason for the fast growth of the prefabricated steel building industry is the fact that steel building manufactur-ers have created prefabricated systems for a wide range of applications. Steel buildings used to be limited to storage facilities and aircraft hangars. Now, steel is used very successfully for structures as small as toll booths and vending ma-chine shelters, and as large as barns and agricultural facilities, workshops, sports facilities, even churches and retail cen-ters. Steel buildings are frequently used in larger buildings like commercial air-craft hangars and sports arenas, where a large clearspan space is required. (Cle-arspan is an interior space of a building where the roof is supported by the bor-dering structural walls and framework, and not with columns.)

Steel provides some other ben-efits in many circumstances. Generally speaking, prefabricated steel buildings can also be erected more quickly than traditionally constructed buildings. As-suming that the prefabricated kit does not require significant customizing, the project’s design phase is reduced considerably with the use of the steel building system. While this is true for the design phase, site preparation and construction phases for larger steel buildings are normally comparable with similarly sized tilt-up structures. Perhaps the main reason for the expanding the use of steel buildings is construction cost. Assuming that the building fits the parameters and limitations of what is appropriate for steel, prefabricated steel building kits are generally less expensive than cus-tom-designed structures built using traditional construction or even tilt-up construction. Also, with the use of fin-ishes, facades and other wall claddings, builders can craft beautiful facilities that avoid the traditional “tin shed” look associated with steel buildings. For smaller warehouse, industrial and commercial projects, particularly those fewer than 50,000 square feet, these benefits make steel buildings an extremely attractive alternative for the cost-conscious building owner. Also, steel buildings are frequently the right choice for larger buildings where a large clearspan space is required.

By Rozaiman Hassan

Manager Construction Technology

Development Division

The term “steel building” is often associated with simple storage sheds and basic structures. With advancements in the industry over the past forty years, however, steel buildings have broken that stereotype and are being used for an ever-growing list of larger and more complex applications. Steel has found its way into advanced farm buildings, riding arenas, aircraft hangars, commercial centers and more.

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IBSDIGEST 3

Precasters who do their own installation know there are procedures required to achieve a high level of quality, customer satisfaction and, most important, safety. Since every installation is unique, proce-dures may vary and can become com-plex. Every company develops its own special way of installing precast. The methods, tools, and supplies used are usually tailored after performing many installations. Networking with other precasters is often the best way to de-termine efficient procedures. To make installations run smoothly, it is best to have experienced workers. Plants should take the initiative and train employees, developing them into highly skilled installers. This goes for foremen, welders, crane operators, and the whole crew. If procedures are kept simple and consistent, installation work-ers can achieve efficient, safe, and cost-effective installations while improving their track records each time.

Planning

Installation is all about planning. You need to determine the best routes and time to the site, access to the site, ground conditions and size of the site before installation works can be done.

Site limitations can lead to difficult and time-consuming installations that may require special lifting hardware and ad-ditional machinery. These will add costs to installation in your quote. It is a good idea to make detailed checklists of all the supplies that will be needed at the job site. Big, complex jobs or jobs located at a fair distance from plants will require a more extensive list than smaller or closer distance jobs. It is always better to come prepared than to send someone to scout for supplies and materials during the installation. The most important aspect of an installation is the safety of your work-ers and anyone on or near the jobsite. Installer must have a detailed safety pro-cedure in their method of statement for installation that meets all Department of Occupational Safety and Health (DOSH). Other than that, Crane operators also must be certified to meet DOSH require-ments. The hazards associated with a pre-cast installation procedure can be very different from other type of works at site. The main thing for workers to keep in mind is to be constantly aware of their surroundings. Workers should practise clear and concise communica-tion, know the rules and regulations,

and watch out for others.

JOKEAn engineer, doctor, and lawyer

golfing. A pastor, a doctor and an

engineer were waiting one morn-

ing for a particularly slow group of

golfers.

Engineer: What’s with these guys?

We must have been waiting for 15

minutes!

Doctor: I don’t know, but I’ve

never seen such ineptitude!

Lawyer: Hey, here comes the

greens keeper. Let’s have a word

with him. [dramatic pause] Hi

George. Say, what’s with that

group ahead of us? They’re rather

slow, aren’t they?

George: Oh, yes, that’s a group of

blind fire fighters. They lost their

sight saving our clubhouse from a

fire last year, so we always let them

play for free anytime.

The group was silent for a moment.

Lawyer: That’s so sad. I think I

will say a special prayer for them

tonight.

Doctor: Good idea. And I’m go-

ing to contact my ophthalmologist

buddy and see if there’s anything

he can do for them.

Engineer: Why can’t these

guys play at night?

Precast Installation PROCEDURES

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ISSUE • JULY – SEPTEMBER 2005

4 IBSDIGEST

The following are just a few safety pro-cedures to follow for installation:

• Workers should at no time be

underneath a suspended product.

• When aligning products, use

objects like 2x4s, bars, shims,

wedges, or other tools to stop the

precast from hitting other objects.

Do not use your hands or feet!

• When working at heights, make

sure all safety equipment is used

properly at all times, no matter how

long the task may take.

• Use ladders according to

manufacturers' recommendations

and secure when appropriate.

• If work is to be done in excavations,

make sure that the shoring is

adequate.

Successful Installation Requires Teamwork

Once a contract has been awarded, a meeting should be held with those in-volved with the job construction prior to installation. The meeting should cover aspects such as site access, product size and weight limitations, installation scheduling, storage issues, and liability issues. It is crucial that owners and other parties of the construction phase un-derstand the precast installation proce-dure and also how the finished product should function and look. This makes the process easier for everyone and many times ensures timely payment. Delivery trucks must have clear ac-cess to the site and be able to maneuver around the site safely, without caus-ing any product damage. The site area must accommodate product handling and possibly storage. For lengthy jobs, products may need to be stored in ar-eas where they are protected and where they do not interfere with other work on site. A critical hazard to document is overhead wires. The site must have suffi-cient room for a boom or crane to move product around without coming in close proximity or in contact with any wires. If any underground utilities exist, their location must be known and marked. A

well-drained, stable site is necessary in order to support trucks, cranes and their outriggers.

Scheduling

Scheduling the installation can range from simple to complex for jobs and in-volve many construction phases. Sched-ules should be reviewed and agreed upon by the general contractor and/or the construction manager. The precast schedule should include detailed installation sequencing informa-tion. The procedure should allow for as few crane moves as possible. Before the precast product leaves the plant yard, determine the order in which pieces are needed on site. At the site, pieces can be easily installed in the predetermined order if they have been shipped in the correct order. An experienced installer will prove helpful in these situations, especially if it is necessary to alter the order. Prior to delivering precast prod-uct and having expensive cranes, other equipment, and installation crews show up at the site, it is essential that the site be properly prepared. The more site preparation you do, the smoother, and it is hoped, less costly the installation will go.

Lifting systems

Most precast units can be installed us-ing standard two- and four- point picks. If products do not need to be flipped or turned vertically, they can be lifted straight off of truck beds and into their final location. Very large and heavy or odd-shaped units may require more complex lifting systems. If units must be flipped vertically and rotated, more spe-cialized lifting apparatus will need to be hooked up to the crane. Most lifting apparatuses consist of wire ropes or chains employing spread-er bars, hooks, shackles, rolling blocks, closed links, and lifting plates to com-plete the assembly. All hardware should have annual certification to verify capac-ity and safe working loads generally is required. DOSH have strict regulations on lifting systems.

Connections or threaded anchor

holes should be free of debris. Make

sure inserts are also clean and greased if

necessary. Check for burrs on threaded

inserts. Do not over tighten bolts, es-

pecially ones close to product edges,

and protect the precast product from

chipping when aligning. Wood, rubber,

wedges, and plastic shims work well for

this.

Sometimes, location elevations, pins,

holes, or attachments may be incorrect.

To attach products using bolts or plates,

expansion bolts may be inserted into

the precast in alignment with structural

connections. In this case, make sure

holes are drilled at structurally sound

locations. It is sometimes inevitable that

steel will be encountered upon drilling.

Or, new plates may be welded either to

the precast or on the fixed structure.

Chemical anchors (resin capsule or ep-

oxy anchors) can be used in place of

expansion anchors for use with heavy

loads. However, excessively high heat

can degrade these chemical anchors.

Be aware of manufacturers load ratings

and recommendations. If structural con-

nections require field modification, an

engineer should be consulted.

If foundation elevations or existing

product dimensions are wrong, either

they will have to be fixed or the precast

may need to be cut to fit. Incorrect base

elevations that prohibit pipe or other

utility connections will also likely require

modification or new holes will have to

be cut in the precast.

Installing products such as lintels

and windowsills can be a complex pro-

cess because of the nature of their fi-

nal locations. Often, the surrounding

pieces are already in place. Cases where

product must fit vertically in between

existing structures can also be complex.

Since the product is usually lifted from

points either on top or on the back of

the product, the lifting devices will likely

have to be disconnected prior to the

complete installation of the product.

Remember, you do not want to damage

the product or jeopardize its structural

integrity.

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IBSDIGEST 5

Bracing and stabilizing Certain architectural and building ap-plication precast units may require tem-porary bracing to stabilize them against loads like wind, seismic movement, eccentric dead loads, incomplete con-nections, and possible impact from con-struction equipment or other precast members. Bracing should already be stored at the job site and readily avail-able when needed. Once a piece of precast is erected and while the crane or boom still carries the load, the bracing can be attached. At the ground, bracing must be posi-tioned to ensure that the unit remains in the proper location. Most bracing can be adjusted by turnbuckles, by changing its position, or by other adjusting methods. Bracing should not be removed until the precast units are within the acceptable placement tolerances and the perma-nent connections have been made.

Welding Some precast component requires weld-ing at their joints. Only certified weld-ers should perform welding. All welders should be competent personnel. Often it is necessary to have connections welded immediately after product placement. It then becomes crucial that adequate workspace is available for both parties to work together without getting in each other’s way or getting weld cables wound around other gear. Welds should be visually checked for quality when complete. If the connec-tions will be exposed to weather, they and the weld should be coated with a protective coating. Remember that welding certain materials, such as galva-nized metal, can be toxic and should be avoided.

Grouting

Grouting is done either prior to precast placement or after. Grouting prior to placement is usually for products that incorporate cast-in dowels that slide into predrilled holes or sleeves. Grout mixtures should be placed just before the units are installed into clean, pre-wetted holes. Pre-wetting prevents the dry concrete from absorbing grout mix-ture water. Once precast units are in their proper location, further grouting may

be required. A number of methods are used for this. If dowels project up into the precast, grout may be pumped in through ports surrounding the dowels. The grout is pumped into the bottom port until it flows out of the top. This ensures the removal of air voids. These ports then need to be sealed with non-absorptive stoppers. Dry packing is a grout placement method used to fill gaps or joints. At the end of the day, workers should tidy up work areas, clean up any mess-es, put away tools, and organize mate-rial and supplies for the next day if the job is not complete. A brief production

JOKE

meeting should be held to determine the next day’s schedule, what supplies and materials will be needed and which ones have to be ordered. Having these meetings will help workers work more efficiently and feel more confident that they know what’s required to achieve a quality finished job. Whether your precast products will be underground or above ground, a quality installation will be evident. On-time, quality installations with a great safety record will impress the parties in-volved in the construction and the own-er, as well as build the esteem of your installation crew. By achieving these, your company will get the reputation it deserves and also increase your chances of getting the next job. You will also help give the industry a good name.

Sources: MC Magazine 2001 – Precast Installation ProceduresBy Rofizlan Ahmad

Manager Construction Technology

Development Division

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6 IBSDIGEST

INTRODUCTION

The construction industry is considered as inefficient and highly labour intensive activity. Conventional method using tra-ditional brick and mortar give low and inconsistency quality since workmanship plays the main role, in which again rely-ing on the skills of the labour. A study done by Waleed et al. in 1997 stated that, in order to achieve Malaysian plan target using the present conventional building system, it will require an exces-sive workforce, since on average only one house is completed per year per worker (one house/year/worker). More-over, the required quality cannot be achieved, because of poor quality con-trol at the site. In order to overcome the present problems, the mass production of housing under high quality control is required in which is the termed of In-dustrialized Building Systems (IBSs). A pre-requisite for IBS is the adop-tion of Modular Coordination by all parties from the submitting technical consultants to the approving authori-ties. Modular Coordination is a concept of coordination of dimension and space, in which buildings and components are dimensioned and positioned in terms of basic units or modules, known as ‘1M’ which is equivalent to 100mm. It is in-ternationally accepted by the World ISO Standard and many other countries. In Malaysia, Modular Coordination is hard-ly used in building design. The main advantages of using IBS, according to a report published by the Malaysian Ministry for Local Govern-ment and Housing (Ministry 1997), are speed of construction, quality, and eco-nomic advantage, all of which are re-quired to meet such a large demand for housing. In promoting the use of IBS and MC, CIDB took a lead to role and formulate a road map for improving the construction output by addressing five

strategic issues including manpower, materials, management, monetary and marketing. This roadmap emphasised the use of MC in achieving standardisa-tion in the building industry and subse-quently increasing the use of IBS com-ponents. While promoting the develop-ment and use of new and relevant tech-nology in the process of nurturing con-struction industry players towards global competitiveness, CIDB strongly insisted the use of labour reducing systems in order to reduce the reliance on foreign labour in the local construction indus-try.

CONSTRUCTION IT PERSPECTIVES ON IBS

In achieving the above challenge, CIDB aims to develop an integrated MC-based design system by the year 2007. How-ever, several issues have to be resolved at the earlier stage especially when in-volving the use of software applications and the integration of these applica-tions. For instance, the software appli-cations of the IBS, which are concerned with the data and information available on the system, users, clients, establish-ment of manufacturing and assembly layout and process, and allocation or resources and material, have received little attention. Therefore, there is a dire need to overcome the shortage in the software applications of the building system research. Software applications of the building system research utilize accumulated technical knowledge and the best technical foresight; this is in order to improve building performance, make building less costly to own, make them safer to build and safer to live in, build and use them with less waste of resources and less pollution of the en-vironment, and improve the quality of private and public lives.

The greatest economy and efficiency of construction can be achieved with a minimum number of operations on site. This includes minimizing assembling re-petitive components, continuous process and optimizing the start-stop activity. Hence, a proper construction sequence is required, not only for speeding-up the construction, but also giving more ad-vantages such as flexible solutions that can help them to avoid collision in time and space during the realization of a project. This can be achieved by using software application to analyze all phas-es of the future project at the planning stage to anticipate any conflicts that may occur and to elaborate on the opti-mal project scenarios. Traffic time on the site can be kept to minimum by a com-puter system that schedules and moni-tor the time frame of deliveries through specific gates and specific hoist4. Extensive literature review indicates that the above features stated above currently either did not exist or did not achieve to the expectations such as MC Checker (MC2), in which will only check-ing the percentages of MC complaints and the buildability of a design drawing without the integration with the actual design (architectural & structural). By having an integrated design approach; processing time and the cost of produc-tion can be optimized. JKR’s experience also indicates the need of an integrated design approach where it is a necessity for design teams to work together in an integrated approach from initial design stage to optimize the design parameters and avoid the time consuming to re-de-signs.

CONCLUSION

It is essential to have such an inte-grated MC-based system which will demonstrates the potential of linking the modern design and manufacturing methods such as CAD/CAM, together with systematic quality control and project monitoring systems. By having these features, a total solution for IBS and MC-based design solution can be achieved for improving the Malaysian construction industry productivity and output especially on realising the Gov-ernment intention for making the Ma-laysian construction industry towards industrialization.

By Dr. Che Wan Fadhil Principle IT Consultant of EMOST Consult.

Realising The Industrialisation Of Malaysian Construction Industry:

CONSTRUCTION IT PERSPECTIVE

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INTRODUCTION

Prefabrication of building components is not a new concept: Even the building blocks of the great Egyptian pyramids were prefabricated to the correct size at the quarry to reduce the weight for the transportation. Traditional farm houses in Europe were since the Middle Ages partly pre-fabricated and built in 3 feet modules and the building industry in USA very early planned to produce a kind of turn-key prefabricated timber houses as a box system. But in UK the well known Crystal Palace represents the first fully dimensional coordinated, prefabricated building system based on cast-iron com-ponents covered with a climatic screen of glass. The Crystal Palace from 1851 is considered the ‘mother’ of all industrial-ized building systems: Extremely simple layout and design based on a 24 feet grid system and constructed of two ma-terials: Cast iron and glass. The 72,000 square meter exhibition building was designed and built in 6 months only, an achievement that even today 154 years later would be remarkable.

CONCRETE

Some years before the Crystal Palace was built British engineers rediscovered the method the Romans used to produce ‘Roman Cement’, a water proof plaster that was made by burning volcanic ash and lime stone together. The production method was further developed into the

production of what we today call Ordi-nary Gray Portland Cement. The process was kept as a strategic military secret for some years but eventually the pro-duction method was generally known and this new material spearheaded the development of the contemporary in-dustrialized building industry. The idea of reinforcing concrete with embedded steel came from a production of pre-cast planter boxes in France. Thus the most versatile construction material, re-inforced concrete, was developed and ready for use. The abilities and properties of rein-forced concrete was quickly explored and new ways of design and calculation developed for the main structure of cast in situ building structures. By the end of the 19th century claddings and deco-rative structural building components were precast in what was called ‘recon-structed stone’ due to the strength and durability of the components. As the general industrialization of production picked up speed in the 20th century mass produced concrete components became increasingly popular and the technique of design and production fur-ther developed.

INDUSTRIALIZATION

Assembly belt production of cars in the United States and the rationalized tex-tile industry in the United Kingdom are often proclaimed as forerunners for the industrializing of the building sector. The concept of planning, design and man-

agement for prefabrication and mass production was already well developed for other industries and ready to be applied to the building industry. Large scale prefabrication of major building parts, such as walls, slabs and façade components, started in countries which had already obtained experiences from industrializing other industries. The real step forward for the pre-fabricated concrete housing technique took place in Europe shortly after the Second World War. It was a change in people’s demands for housing and also a change in family structure which influ-enced the building sector. People were prepared and able to pay more for living space and at the same time youngsters wanted to move out from their parents’ home much earlier than before. This created a demand for new housing that the traditional construction method had no possible way to satisfy. The Building Authorities in many Eu-ropean countries, especially in Finland, the Netherlands, France and Denmark, realized that the only way to overcome the lack of quality housing facilities due to the increasing demand was to indus-trialize the housing production. Such a concept would also ensure that a rapidly growing building sector still could pro-duce houses of high quality and at the same time with an increasing productiv-ity.

THE DANISH EXPERIENCE

In Denmark the implementation of precast modular housing systems were launched in 1958. In the first 9 years

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ISSUE • JULY – SEPTEMBER 2005

8 IBSDIGEST

from 1957-1967 the total number of units build per year went up from 21,000 to 45,000, an increase of 115%. At the same time the labor productiv-ity in the building industry increased with 75% and most of the work on the building components was moved from the construction site to the prefabrica-tion factories. This meant higher sala-ries, job security and improved safety and working conditions for the work-ers. As a consequence work in the con-struction industry became an ‘accepted occupation’ and very little foreign labor was needed in Denmark. The reason for these impressive fig-ures was mainly the fact that a clause was added to the Danish Building Regu-lations saying: ‘Dwelling houses erected for rental purposes shall be designed in accordance with Modular Regulations for Building Works’, as defined in Dan-ish Codes. If the project was not modu-lar designed it would not get a building permission and since 85% of houses built at that time were for rental purpos-es consultants were forced to learn how to design modular building projects. With this clause it was mandatory to produce modular designs but still volun-tary to use prefabricated components or

not. But very soon the modular design condition had a great impact on the en-tire construction industry in the country. As most projects were now prepared for the use of modular slab components and walls with standard design a new mar-ket was created. It now became tempt-ing and economical viable for contrac-tors and investors to establish factories for producing precast components for especially residential buildings.

In the very beginning the Precast-ers and the Structural Engineers more

or less dictated the shape of the precast buildings. The Architects at first found it below their ‘dignity as artists’ to deal with structure and buildability and was consequently left with only the outer 2-4 mm façade skin to play with in design for patterns, profiles and color. This created many boring buildings and gave Precast a bad reputation as a low cost and ‘boxy’ design and construction suited for cheap mass housing only.

CONCLUSION

The conditions in Europe, USA and Aus-tralia for the design of precast buildings have now changed and the Architects have won back the role as the leader of the precast design team by learning

Features

how to adapt the precast construction method in the design. Developers of precast buildings surely have recognized the benefit of implementation of the ‘integrated design concept’, meaning a strong corporation between Architects, Structural and Mechanical Engineers, Precasters and Contractors from the very first stage of the design. For many years now durable and pleasant look-ing buildings have been designed and implemented using prefabrication tech-nology both for load bearing structures and for claddings. The benefits of using Industrialized Building Systems are now appreciated by clients all over the world: Higher quality, faster construction time, reduction in labor force, higher produc-tivity, reduction in costs and less main-tenance. The development of the building in-dustry in Malaysia towards industrializa-tion and prefabrication has just picked up speed with the government’s drive for ‘Industrialized Building System’, IBS through CIDB and other channels. Seen with the experience from the rest of the industrialized world developers, contrac-tors and consultants in Malaysia have no choice but to look forward and prepare their projects for IBS.

by Poul Bannow Mork, IBS Alliance Sdn Bhd

JOKE Engineers and Lawyers

On a college field trip, four Engi-

neering and four Pre-Law students

were travelling on the same train.

The law students each had a tick-

et, but the Engineers had but one

ticket amongst them. One of the

Engineers shouted “conductor’s

coming!”, and the four Engineers

crowded into one of the bathrooms.

The conductor comes by and knocks

on the bathroom door saying “Tick-

ets, please”. The Engineers slip their

one and only ticket under the door.

The conductor punches it an moves on

to the next car.

On the return trip, the four Lawyers,

impressed by the Engineers’ trick, pur-

chase only one ticket. The Engineers,

however have no tickets at all!. Sud-

denly, one of the Engineers shouts

“Conductor’s coming”. All four Engi-

neers head for the bathroom, and all

four lawyers crowd into the other one.

Then, one of the Engineers slips out

of his bathroom and knocks on the

other bathroom door saying “Tickets,

please”. The lawyers then slip their

only ticket under the door, and the

Engineer then picks up the ticket and

joins his friends, waiting for the real

conductor.

ISSUE • JULY – SEPTEMBER 2005

IBSDIGEST 9

Apakah Manfaat Menggunakan IBS?

Manfaat utama yang diperolehi melalui penggunaan sistem ini adalah seperti berikut:• Produk yang berkualiti tinggi dan

pembaziran yang minimum kerana persekitaran kerja di kilang lebih mudah dikawal;

• Penghapusan acuan kayu konvensional dan pengurangan ketara penggunaan penyangga melalui penggunaan elemen pasang siap atau sistem acuan bagi proses tuangan di tapak;

• Platform kerja yang teguh dan selamat dihasil melalui elemen pasang siap;

• Penyiapan yang lebih cepat berikutan pengenalan komponen yang menggantikan pembinaan in-situ;

• Tapak pembinaan lebih teratur, bersih dan selamat berikutan pengurangan sampah binaan, pekerja dan bahan binaan ditajak;

• Jumlah kos pembinaan yang lebih rendah berikutan manfaat yang dicapai daripada faktor-faktor di atas.

Poster Promosi IBS sering menyatakan bahawa penggunaan kaedah IBS dapat

mengurangkan kos projek. Tetapi melalui pengalaman saya, tidak. Sila ulas.

Jika anda membandingkan hanya kos bahan sahaja, memang benar kompo-nen IBS adalah lebih tinggi berbanding kos in-situ. Pengilang IBS perlu mem-belanjakan sejumlah wang yang besar untuk mendirikan kilang dan dengan demikian perlu menyerapkan kos pela-burannya ke dalam harga produk IBS. Walau bagaimanapun, sama seperti produk pengguna lain, kita memang perlu membayar harga yang lebih tinggi untuk mendapatkan jenama bertaraf premium. Dalam pembinaan, IBS adalah sebuah jenama premium kerana ia menawarkan kualiti, produktiviti dan tahap keselamatan yang lebih terja-min. Oleh itu sudah semesti harganya lebih tinggi sedikit. Di samping itu, kita perlu melihat kepada manfaat di dalam penggunaan kaedah IBS. Dengan peng-gunaan kaedah IBS, ia memberi kualiti yang lebih baik maka kos kerja pembai-kpulih dapat dikurangkan. Masa mem-bina yang lebih pendek juga bermakna pulangan daripada pelaburan (ROI) bo-leh dicapai dengan lebih pantas. Bagi pembeli rumah, ia bermakna mereka boleh mengelak daripada membayar lebih banyak faedah kepada bank. Bagi para pemilik kilang atau pejabat pula, mereka boleh memulakan operasi den-

gan lebih cepat. Jika dilihat dari sudut yang lebih luas lagi, bayangkan betapa Kerajaan boleh menjimatkan wang ber-bilion Ringgit dengan mengurangkan pergantungan kepada pekerja asing dan pengaliran keluar matawang Ring-git ke negara luar.

Saya Tidak Yakin Terhadap Prestasi Struktur Bangunan Yang Dibina Menggunakan Kaedah IBS. Adakah Bangunan Tersebut Seteguh Struktur Binaan Konvensional? Saya Juga Masih Ragu Cara Pembinaan Ini Boleh Menjamin Tiada Kebocoran.

IBS hanya merupakan kaedah pembi-naan sahaja. Rekabentuk sebenarnya menentukan keteguhannya, sama sep-erti struktur konvensional. Perbezaan-nya adalah struktur IBS memerlukan pengiraan tambahan bagi peringkat pembinaan. Bangunan yang dibina menggunakan kaedah IBS juga mempu-nyai prestasi struktur yang serupa sep-erti keteguhan bangunan yang dibina mengikut kaedah tuang-in-situ. Perin-cian keluli pada sambungan IBS juga merujuk kepada asas yang sama seperti yang ditetapkan dalam kod rekaben-tuk. Sebagai contoh, Papak Separuh konkrit pratuang 65mm dengan tuan-gan tambahan konkrit in-situ 75mm

Features

Soalan-soalan Yang Seringkali Ditanya (FAQs) Mengenai Sistem Binaan Berindustri (IBS) dan Kordinasi Modular (MC)

Apakah IBS?

Sistem Binaan Berindustri (IBS) juga dikenali sebagai pembinaan pasang siap: sistem pembinaan di mana komponen diperbuat di kilang, di tapak atau di luar tapak, diangkut dan kemudian dipasang menjadi sebuah struktur dengan kerja yang minimum. Lima jenis IBS yang biasa digunakan di Malaysia adalah sistem kerangka panel dan kekotak konkrit pratuang, sistem kerangka keluli, sistem kerangka kayu pra-siap, sistem acuan keluli serta sistem blok pratuang.

ISSUE • JULY – SEPTEMBER 2005

10 IBSDIGEST

akan mempunyai keteguhan struktur yang sama dengan papak konkrit tu-ang-in-situ 140mm selagi ia direkaben-tuk dengan kod rekabentuk dan meng-gunakan beban dan bahan yang sama. Beberapa bangunan IBS yang terawal dibina di Malaysia mungkin pernah menggunakan sambungan kering yang berkecenderungan untuk bocor dengan mudah berbanding sambungan. Walau bagaimanapun, kebocoran sebenarnya tiada kaitan dengan sistem IBS, tetapi sebaliknya adalah berkaitan dengan ha-sil kerja yang tidak memuaskan. Tanpa melakukan kerja konkrit dan kerja ka-lis air dengan sempurna, pembinaan tuang-in-situ juga boleh berlaku kebo-coran. Sungguhpun diperbuat dengan tahap kualiti paling tinggi, komponen Completely Knocked Down (CKD) kereta Mercedes Benz sekalipun akan mengalami kegagalan sekiranya kerja pemasangan tidak dilakukan mengikut prosedur yang betul;

Apakah Kordinasi Modular? Adakah Ia Merupakan Satu Lagi Teknik Pembinaan?

Kordinasi Modular atau MC adalah sebuah sistem dimensi. Ia merupakan konsep koordinasi dimensi dan ruang di mana bangunan dan komponen di le-takkan kedudukannya berasaskan kepa-da unit atau modul asas dikenali sebagai ‘1M’ yang bersamaan dengan 100mm. Sebagai contoh, daripada menggu-nakan ukuran 2413mm, yang lebih su-kar diukur, ia akan digenapkan kepada 2400mm. Penggunaan MC adalah satu faktor penting dalam aplikasi IBS se-cara berkesan kerana ia melengkapkan pengindustrian melalui pempiawaian dan peningkatan produktiviti.

Adakah Kita Mempunyai Standard Malaysia (MS) Bagi MC Dan Di Mana Saya Boleh Dapatkannya?

MS bagi MC dipanggil MS 1064 (Pan-duan Kepada Koordinasi Modular dalam Bangunan). Ia mengandungi 10 bahagian dan berasaskan kepada stan-

dard ISO yang diiktiraf di peringkat an-

tarabangsa. Anda boleh membelinya

daripada SIRIM Berhad, ejen yang di-

lantik oleh Jabatan Standard Malaysia

(DSM) untuk membangun, mengedar

dan menjual Standard Malaysia.

Adakah Benar Bahawa Dengan Menggunakan MC, Kita Menghadkan Bangunan Kepada Bentuk Empat Persegi Sahaja?

Tidak benar sama sekali. Ia bergantung

kepada daya kreativiti dan pilihan per-

ekabentuk. Rekabentuk kuarters JKR

yang dibina menggunakan ukuran MC

dan kaedah IBS adalah buktinya. Begitu

juga dengan beberapa rekabentuk ban-

gunan lain yang dibina di negara maju

seperti Perancis, Singapura, Denmark

dan Finland; Sebenarnya, kebanyakan

bangunan awal yang dibina menggu-

nakan MC dan IBS adalah bangunan

yang dibina sekitar tahun 1960an, beri-

kutan program pembangunan semula

selepas zaman perang yang dilakukan

dengan pesat. Pada masa itu, rekaben-

tuk seni bina minimalis menjadi pilihan;

dan dengan demikian wujudlah banyak

bangunan berbentuk empat persegi dan

fasad yang minimal.

Bagaimana MC Digunakan Bagi Rekabentuk Rumah Teres? Ini Kerana Tapak Tanah Telah Dibahagikan Kepada Bahagian Yang Lebih Kecil Berasaskan Kepada Ukuran Imperial.

Di samping menggalakkan penstandar-

dan dan produktiviti, MC telah diban-

gunkan oleh ISO bagi mempermudah

penukaran dimensi Imperial kepada

Metrik. Panduan bagi penggunaan MC

di tapak yang dibahagikan kepada be-

berapa tapak kecil disediakan dalam

“Modular Coordination Notes; Implikasi

Koordinasi Modular Dalam Undang-un-

dang dan Peraturan Bangunan” dan

“Modular Design Guide”.

Features

Adakah Sebarang Latihan Mengenai IBS dan MC Disediakan?

Ya, kami mempunyai sesi latihan secara

kerap untuk rekabentuk konkrit pratu-

ang serta MC. Kami juga merancang

untuk memulakan kursus rekabentuk

keluli. Sila hubungi kami melalui e-mel

di ibs@cidb.gov.my bagi mendapatkan

maklumat terkini.

Saya Dengar Dalam Ucapan Bajet 2005, Projek Perumahan IBS Dikecualikan Daripada Membayar Levi CIDB. Adakah Fakta Ini Benar?

Projek perumahan dengan kandungan

IBS (IBS Score) yang minimum iaitu se-

banyak 50% akan diberi pengecual-

ian oleh CIDB daripada membayar levi.

Panduan bagi pengiraan IBS Score dise-

diakan dalam penerbitan: Manual for

IBS Content Scoring System (IBS Score).

Sila hubungi Unit Levi di talian 03-2617

0200 bagi mendapatkan keterangan

lanjut mengenai permintaan untuk

mendapatkan pengecualian levi.

Di Manakah Saya Boleh Mendapatkan Bahan Rujukan Mengenai IBS dan MC?

Kami menawarkan pelbagai jenis pener-

bitan mengenai IBS dan MC. Ini ter-

masuk Standard Industri Pembinaan,

katalog produk, manual dan prosiding.

Anda boleh membelinya dari semua

Pejabat CIDB Negeri atau Wilayah serta

dari kaunter di Tingkat 7, Ibu Pejabat

CIDB di Kuala Lumpur. Beberapa pener-

bitan lain juga tersedia untuk dimuat

turun secara percuma daripada laman

web kami di: www.cidb.gov.my

Ir. Shahrul Nizar Shaari

Pengurus, Bahagian Pembangunan

Teknologi, CIDB Malaysia.

ISSUE • JULY – SEPTEMBER 2005

IBSDIGEST 11

CIDB telah mengadakan program Road-

show IBS yang ke 4 di Wilayah Sabah

pada 19 hingga 21 Julai 2005 bagi

memberi kesedaran awal tentang Indu-

trialised Building System (IBS) dan Kor-

dinasi Modular (MC). Program tersebut

telah dirasmikan oleh Y.B Datuk Ray-

mond Tan Shu Kiah, Menteri Pemban-

gunan Infrastruktur Sabah. Seramai 130

peserta daripada sektor kerajaan dan

swasta telah menghadiri program terse-

but. Program ini telah diadakan di Hyatt

Regency Kinabalu, Kota Kinabalu. Ia

merupakan salah satu daripada aktiviti

promosi yang telah dirangka di bawah

Roadmap IBS 2003-2010 yang telah

disahkan oleh kabinet sebagai satu do-

kumen pelan induk untuk mengindus-

trikan sektor pembinaan Malaysia. Pro-

gram ini merangkumi Seminar ke arah

Mengindustrikan Industri Pembinaan

News

Program Promosi IBS WILAYAH SABAH

Malaysia, Latihan Kordinasi Modular

dan Latihan Rekabentuk Konkrit Pra

tuang serta pameran mini produk IBS

yang terdapat di pasaran.

Program ini bertujuan untuk meng-

galakkan pembinaan secara berindustri

sebagai satu alternatif kepada kaedah

konvesional (insitu), melalui IBS dan MC

khusus kepada semua peserta industri

pembinaan seperti penggubal dasar,

agensi pelaksana, pemaju, perekaben-

tuk, pengilang, kontraktor, pembekal,

penyelidik dan pihak-pihak lain yang

terlibat.

Dengan adanya program ini tahap

kualiti, produktiviti, keselamatan dan

pergantungan berlebihan kepada pe-

kerja asing yang tidak mahir dapat

diperalaskan dengan pembangunan

masa depan Malaysia. Seperti yang

dinyatakan di dalam Ucapan Bajet

2005 dengan menguatkuasakan peng-

gunaan IBS di dalam projek bangunan

kerajaan dan pengecuali levi CIDB un-

tuk projek IBS. Program ini telah turut

memaparkan latarbelakang program

IBS, Roadmap IBS dan kajian kes men-

genai penggunaan IBS di Malaysia. Di

samping itu turut diadakan mengenai

penentuan kandungan IBS di dalam ses-

uatu projek melalui Manual IBS Score.

ISSUE • JULY – SEPTEMBER 2005

12 IBSDIGEST

Promosi Sistem Binaan Berindustri (IBS) Sarawak • Seminar • Kursus Koordinasi Modular • Kursus Rekabentuk Konkrit Pratuang

Announcements

Disokong oleh:

Kementerian PerumahanSarawak

Dianjurkan oleh:

Lembaga Pembangunan Industri Pembinaan Malaysia

Sarawak HousingDeveloper Association

IEMSarawak Branch

PAMSarawak Chapter

PKMMSarawak

PROMOSI SISTEM BINAAN BERINDUSTRI (IBS)WILAYAH SARAWAK

KE ARAH PEMBINAAN BERKUALITI DAN PENGURANGAN PERGANTUNGAN TENAGA BURUH26 – 28 SEPTEMBER 2005HOLIDAY INN, KUCHING

Dirasmikan olehYB Dato Sri Abang Haji Abdul Rahman Zohari Bin Tun Abang Haji Openg

Menteri Perumahan Sarawak