BLD 511 LECTURE NOTE

INDUSTRIALIZED BUILDING SYSTEM (IBS)

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The traditional construction method which is commonly practiced, where based on the client

brief, the architect will produce an architectural design, and pass it to the structural engineers.

After completing the structural design, the detail specification will be passed to the quantity

surveyor to produce costs and the bill of quantities. Later, these documents will be passed to

the main contractor who will then discuss the matter with the client and in the end take

responsibility for the construction (assembly) of the building structures. The shortcoming of

this method is, high in cost of construction, inability to meet the ever-increasing huge

housing demand within a short space of time, requires a large workforce (mostly unskilled)

and failed to produce acceptable quality construction products. In an attempt to address these

issues, the Construction Industry Development Board (CIDB) tries to encourage a paradigm

shift in the construction process from the conventional or traditional approach to

industrialization perspective. One of the efforts is to actively promote the adoption of the

Industrialized Building System (IBS). According to the IBS Roadmap, industrialisation is a

process of social and economic change whereby a society is transformed from pre-industrial

to industrial state. It is part of a wider modernisation process through the gainful utilisation of

relevant and viable technologies.

The term IBS is widely used by the practitioners, researchers and the government in most

countries to represent industrialization in construction. The term, however, cover a very wide

scope which includes the application of onsite systems and one cannot distinguish it properly

with conventional practice. While other terms used to represent construction industrialization

often relates to innovative solution. Current definition by Construction Industry Development

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Board (CIDB) includes low-tech solutions and other practices which have already become

common and not substituting conventional practices.

What is Industrialisation?

Industrialization means industrial method employed with reference to mechanization,

standardization and prefabrication.

The International Council for Research and Innovation in Building and Construction (CIB) in

its latest report on industrialized construction linked industrialization with the use of

mechanical power and tools, the use of computerized steering system and tools, production in

continues process, continues improvement of efficiency, standardization of products,

prefabrication, rationalization, modularization and mass production. In the perspective of

construction, industrialization is a part of a wider modernization process through the

development of modern methods of production and technology system, production

operations are mechanized and are focused on mass production and mainly factory

production where work is centrally organized

One of the efforts towards construction industrialization is through the introduction of

Industrialized Building System (IBS). IBS is defined as, “An innovative process of building

construction using concept of mass-production of industrialized systems, produced at

the factory or onsite within controlled environments, it includes the logistic and

assembly aspect of it, done in proper coordination with thorough planning and

integration”.

It literally means that those parts of building that are repetitive but difficult, time consuming,

labour intense to cost at site are design and detailed as standardized components at factory.

The definition also emphasized on coordination between design, manufacturing and

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construction. It is important to note that in this research, IBS involves onsite casting using

innovative and clean mould technologies (steel, aluminium and plastic).

Objective of industrialisation

1. Maximizing production output

2. Improving quality

3. Minimizing labour resources and

4. Cost efficiency.

Terms used to describe IBS

Pre-assembly, Prefabrication, Modern Method of Construction (MMC), Offsite

Manufacturing (OSM), Offsite Production (OSP) and Offsite Construction (OSC). These

concepts are often used interchangeably when describing the characteristics of industrialized

construction. Nonetheless, regardless of the terms, the idea is the same which refers to

manufacture of structure components for the construction of buildings in a control

environment rather than doing on site.

Categorization of Terminologies.

Terminology Category Term

Off Site (OS) Offsite Production (OSP)
✓ Offsite manufacturing (OSM)
✓ Offsite Fabrication (OSF)
✓ Offsite Construction
PRE Pre-assembly
✓ Prefabrication
✓ Prefab
Modern Method (MM) Modern Methods of Construction (MMC)
✓ Modern Methods of House Construction
✓ Modern Methods of House Building

Building System Building

✓ Non-traditional Building

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 ✓ Industrialized Building

IBS CLASSIFICATION

The classification is based on material, process and system

1) Frame System (pre-cast or steel): The framed structures are defined as those structures
that carry the loads through their beams and girders to columns and to the ground

*Pre-cast Concrete Framing, Panel, and Box Systems

Pre-cast columns, beams, 3-D components (balconies, staircases, toilets, lift
chambers),permanent concrete formwork.
*Steel Formwork Systems
Tunnel forms, beams and columns moulding forms, permanent steel formwork.
*Steel Frame System
Steel beams and columns, portal frames, roof trusses.
*Prefabricated Timber Framing Systems
Timber frames, roof trusses.

2) Panellised System: In panel system, load are distributed through large floor and wall
panels.

3) Onsite fabrication

4) Sub-assembly and components

5) Block work system: Interlocking concrete masonry units (CMU), lightweight concrete
blocks.
6) Hybrid System

7) Volumetric and Modular System: The box systems include those systems that employ
three-dimensional modules (or boxes) for fabrication of habitable units are capable of
withstand load from various directions due to their internal stability.

No General System System Production Material

1 Frame system Light weight frame Wood, light gage metals
Medium light weight frame Metal, reinforced plastics,
Heavy weight frame laminated wood, Heavy steel,
concrete
2 Panel system Light and medium weight Wood frame, metal frame, and
Panel 1 composite material

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 Heavy weight panel (factory Concrete
produced)
Heavy weight panel (tilt up Concrete
produced on site)
3 Box system Medium weight box Wood frame, light gage metal,
(modules) (mobile) composite

Medium weight box Wood frame, light gage metal,

(sectional) compositeConcrete
Heavy weight box (factory Concrete
produced)
Heavy box (tunnel produced Concrete
on site)

Essential characteristics of IBS

1 Closed System
A closed system can be classified into two categories, namely production based on client’s

design and production based on precaster’s design. The first category is designed to meet a

spatial requirement of the client, that is the spaces required for various functions in the

building as well as the specific architectural design. In this instance, the client’s needs are

paramount and the precaster is always forced to produce a specific component for a building.

On the other hand, the production based on precaster’s design includes designing and

producing a uniform type of building or a group of building variants, which can be produced

with a common assortments of component. Such building includes school, parking garage,

gas station, low cost housing, etc. Nevertheless these types of building arrangement can be

justified economically only when the following circumstances are observed.

a) The size of project is large enough to allow for distribution of design and production costs

over the extra cost per component incurred due to the specific design.

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b) The architectural design observes large repetitive element and standardisation. In respect

to this, a novel prefabrication system can overcome the requirement of many standardised

elements by automating the design and production process.

c) There is a sufficient demand for a typical type of building such as school so that a mass

production can be obtained.

d) There is an intensive marketing strategy by precaster to enlighten the clients and designer

on the potential benefit of the system in term of economics and noneconomic aspects.

2 Open System
In view of the limitations inherent in the closed system, an open system which allows greater

flexibility of design and maximum coordination between the designer and precaster has been

proposed. This system is plausible because it allow the precaster to produce a limited number

of elements with a predetermined range of product and at the same time maintaining

architectural aesthetic value. In spite of many advantages inherent in an open system, its

adoption experiences one major setback. For example, joint and connection problem occur

when two elements from different system are fixed together. This is because similar

connection technology must be observed in order to achieve greater structural performance.

3 Modular Coordination
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.

The objectives of modular co-ordination are:

a) to create a basis upon which the variety of types and sizes of building components can be

minimized. Through a rationalised method of construction, each component is designed to be

interchangeable with other similar ones and hence, provide a maximum degree of freedom

and choice offered to the designer. This can also be accomplished by adopting a relatively

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large basic measurement unit (basic module) and by limiting the dimensions of building

components to recommended preferred sizes

b) to allow for easy adoption of prefabricated components to any layout and for their

interchangeability within the building. This is achieved by defining the location of each

component in the building with reference to a common modular grid rather than with a

reference to other components. The modular co-ordination for building component apply the

basic length unit or module of M=100cm. This allows the designer to apply this size or its

multiple in the production of building components. Although this concept seems to be easy

for adoption, its application involves a great degree of coordination and adjustment in the

manufacturing process and the interfacing aspects of components.

4. Standardisation and Tolerances

For accomplishing the requirement of modular co-ordination, all components need to be

standardised for production. Such standardisation of space and elements need prescribing

tolerances at different construction stages such as manufactured tolerances, setting out

tolerances, and erection tolerances, so that the combined tolerance obtained on statistical

considerations is within the permitted limits. Production resources can be used in the most

efficient manner if the output is standardised. Then the production process, machinery, and

workers’ training can be best absorbed to the particular characteristics of the product.

5. Mass Production
The investment in equipment, human recourses, and facilities associated with an

industrialisation can be justified economically only when large production volume is

observed. Such volume provides a distribution of the fixed investment charge over a large

number of product units without unduly inflating their ultimate cost.

6. Specialisation
Large production output and standardisation of precast elements allow a high degree of

labour specialisation with the production process. The process can be subdivided into a large

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number of small homogenous tasks. In such working condition, workers are exposed to their

work repetitiously with higher productivity level.

7. Good Organisation
High production volume, specialisation of work, and centralisation of production requires an

efficient and experienced organisation capable of a high level of planning, organising,

coordination and control function with respect to production and distribution of the products.

8. Integration
In order to obtain an optimal result, a high degree of coordination must exist between various

relevant parties such as designer, manufacturer, owner, and contractor. This is achieved

through an integrated system in which all these functions are performed under a unified

authority.

9. Production Facility
The initial capital investment for setting up a permanent factor is relatively experience. Plant,

equipment, skilled worker, management resources need to be acquired before production can

be commenced. Such huge investment can only be breakeven if there is sufficiently demand

for the products. On the other hand, a temporary casting yard or factory can be established at

the project site in order to minimise the transportation costs.

10. Transportation
It is found that casting of large-panel system can reduce labour cost up to 30 percent.

However, these cost savings are partially offset by the transportation costs. The transportation

of large panels is also subject to the country’s road department requirement. These limitations

must be taken into consideration when adopting a prefabrication system.

11. Equipment at Site

For the purpose of erecting and assembling precast panels into their positions, heavy crane is

required especially for multi-storey building. It is therefore important to incorporate this

additional cost when adopting a prefabrication system.

BENEFITS OF IBS

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Industrialised building system has the following benefits when compared to the conventional

construction method.

a) The repetitive use of system formwork made of steel, aluminium, etc and scaffolding

provides considerable cost savings.

b) Construction operation is not affected by adverse weather condition because prefabricated

component is done in a factory controlled environment.

c) Prefabrication takes place at a centralised factory, thus reducing labour requirement at site.

This is true especially when high degree of mechanisation is involved.

d) An industrialised building system allows for faster construction time (less than half of the

time taken in conventional cast in-situ construction) because casting of precast element at

factory and foundation work at site can occur simultaneously. This provides earlier

occupation of the building, thus reducing interest payment or capital outlays.

e) An industrialised building system allows flexibility in architectural design in order to

minimise the monotony of repetitive facades.

f) An industrialised building system provides opportunities for innovative architecture as the

system provide opportunities for designers and builders to explore creative designs using the

IBS

g) An industrialised building system component produces higher quality of components

attainable through careful selection of materials, use of advanced technology and strict

quality assurance control.

SHORTCOMINGS OF IBS

The adoption of IBS is not without its limitations. Below are the shortcoming of an IBS

system.

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a) An IBS system can only be acceptable to practitioners if its major advantage can

supersede the conventional system. However, up to date, there is inadequate corroborative

scientific research undertaken to substantiate the benefits if IBS system. It is therefore,

arguable that the implementation of IBS is particularly hindered by lack of scientific

information.

b) Standardisation of building elements face resistance from the construction industry due to

aesthetic reservation and economic reason. One good example of this is when a 300mm thick

modular standardised floor slab has to be used although a 260mm thick floor slab can achieve

the similar structural performance. This results in wastage of materials.

c) Despite an intensive marketing strategy since 1980’s in some developing countries to

introduce modular co-ordination, its acceptance has received poor responses for the building

industry. As a result, even partial introduction of IBS such as lintels, staircase, etc has not

been possible.

d) A general decline in demand and volatility of the building market for large public housing

projects in most developed countries makes an investment in IBS more risky when compared

with the conventional labour intensive methods. This reason is substantiated by a cheap

imported labour in several European countries.

e) The industrialisation of building process which emphasis is on the repetitiveness and

standardisation cause monotonous “barrack like” complexes that very often turned into

dilapidated slums within several years. This shortcoming is further reinforced by production

defects in building components which are quite frequent in the initial stages of prefabrication.

Such defects resulting from lack of technical expertise and poor quality control cause

aesthetic and functional faults, such as cracks, blemishes, moisture penetration, and poor

thermal insulation in completed buildings.

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f) Prefabricated elements are considered inflexible with respect to changes which may be

required over its life span. This may occur when small span room size prefabrication is used.

g) At university level, students are less exposed to technology, organisation and design of

industrialised building system. The academic curriculum seldom includes courses that

incorporate a thorough and methodological manner, the potential and the limitations

associated with industrialisation in building. As consequences, there is a natural tendency

among practioners to choose conventional methods perhaps with occasional utilisation of

single prefabricated elements.

h) The weakness of existing industrialised building system is still in its cumbersome

connections and jointing methods which are very sensitive to errors and sloppy work. Also,

standardisation of joint and connection detail may impede the evolution of new technology.

i) An adaptation of standardisation requires a tremendous education and training effort.

Hence, requires an initial immense investment cost. This is cited as one of the greater

hindrance to the use of modular coordination.

BARRIERS TO IMPLEMENTATION OF IBS IN DEVELOPING COUNTRIES

Cost and financial barriers

Generally, the preference for IBS adoption depends on many variables. Among them are:

design, standard, volume and consistency. The philosophy of IBS is based on volume or mass

production focusing on the modular system and quality of finished products resulting in the

reduction in the cost of production. Unfortunately, most housing projects in rural and urban

areas were constructed in relatively small and medium scales and there is a general decline in

federal and state government large scale housing development. In addition, IBS construction

also requires specialized equipment and machinery. Since most of the machineries and

materials used in fabricating IBS components are imported from developed countries, the

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costs of producing IBS components and assembling them are not competitive for local

contractors.

Poor Skill and Knowledge

IBS requires high construction precision. Previous studies have indicated that most local

professionals are not fully conversant with modular co-ordination and standardization

concept associated with IBS design and assembling procedures and contractors lack technical

knowledge and experience in the IBS. The skill level of IBS workers is more demanding

compared to the conventional construction methods. Under this system, the demand for on-

site semi-skilled workers, particularly carpenters, bar benders and concreters becomes less.

The system demands more machine-oriented skills, both on sites and in factories. Thus, this

leads to a transformation requiring the restructuring of human resource in an organization in

terms of training and education.

Project Delivery and Supply Chain

IBS manufacturers are normally required to advance about 75% of the capital to manufacture

the IBS components before delivering these components to construction sites. As such

contractors are required to help foot this initial bill. However, the current practice of paying a

contractor between 10% and 25% of the total amount of the contract value as mobilization

fee by the client, before a construction starts is grossly inadequate. The only way for a

contractor to be able to do that is by applying for a bond from a financial institution as a

guarantee to be deposited with the IBS manufacturer. Unfortunately for some contractors,

especially those new to the field, they face problem(s) in securing such bond. This may well

affect the IBS project development process.

Lack of Guideline

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Lack of specific IBS building regulations or standard guidelines for contract documents or

procurement systems in terms of tendering, design, construction and operation of a project.

This lack of structured information will not only affect construction professionals because of

misunderstanding and misinterpreting regulations but also for authorities in terms of project

approval.

Lack of Standardization and Modular Coordination

Another barrier to IBS adoption also stems from poor responses on modular coordination and

standardization concepts from the building industry. Modular co-ordination and

standardization are among prerequisite characteristics underlining the successful

implementation of IBS. For accomplishing the requirements of modular co-ordination, all

components need to be standardized and therefore standard plans and standard component

drawings are required, particularly to aid the production process. This is cited as one of the

principal hindrances to the use of modular coordination.

Connection and Jointing in IBS

A major weakness in IBS is its cumbersome connections and jointing methods: For an

example, poor jointing of prefabricated walls with other prefabricated or in-situ elements may

give rise to water seepage problem in IBS high-rise buildings, especially during a heavy

downpour. This problem worsens if finishes are not chosen and done properly. This may

result in, for example, high moisture movement, incompatible with the other materials like

tiles to peel off the walls.

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