HOW CAN CIDB AND INDUSTRY PLAYERS WORK HAND...

Setia Precast Sdn Bhd

IBS SCORING IN MALAYSIA

HOW CAN CIDB AND INDUSTRY PLAYERS WORK

HAND IN HAND TO PROMOTE USAGE OF IBS

IBS SCORING SYSTEM & CASE STUDY

CONTENT :

1) IBS SCORING SYSTEM2) CASE STUDY 1 – RESIDENTIAL3) CASE STUDY 2 – NON-RESIDENTIAL4) FURTHER ENHANCEMENT TO IBS SCORE SYSTEM5) CONCLUSION

1. IBS Scoring System – IBS Score

First Published : January 2005First Revision : April 2010

Objective :-

To provide a systematic and structuredassessment system to measure theusage of IBS in a consistent way.

2. Emphasis of IBS Scoring System

- The use of fabricated and precast components.- Off-site production of components- The use of standardised components- Repeatability- Modular Coordination (MC) in building MS1064

Components of IBS Scores

Part 1

Structural Systems (Table 1) (50 IBS Points)

Full IBS Factors :- Precast Concrete Columns, Beams &

Slabs- Prefabricated Steel Structures- Timber Framed System

Partial IBS Factors :- Reusable System Formworks for in-

situ concrete structures

Nil IBS Factor :- Timber Formwork

IBS Scoring Attributes

Part 1

Roof (Table 1A)

Full IBS Factors :- Prefab Timber Roof Truss - Prefab Metal Roof Truss

Partial IBS Factors :- Precut Metal Roof Truss

Nil IBS Factors :- Timber Roof Trusses

Total Score for Part 1

Part 2

Wall Systems(20 IBS Points)

Full IBS Factors :- Precast Concrete Panel- Wall Cladding- Prefabricated Timber Panel- Full Height Galss Panel- Dry Wall System- Pre-Assemble Blockwall

Partial IBS Factors :- In-situ Concrete With Reusable

System Formwork- Blockwork System

Nil IBS Factors :- Common Brickwall

Total Score for Part 2

Part 3

Other Simplified Construction Solutions(30 IBS Points)

Emphasis on :

- Utilisation of MS1064 Guidelines

- Horizontal & Vertical Repetition

- Buildability

Case Study 1 - ResidentialSeri Jati Apartment, Setia Alam948 Units, 6 Blocks, 10 Storey Apartment in a single phase development

CONSTRUCTION SYSTEMS

Conventional Construction

- Foundation

- Ground Floor

- Transfer Beam

- RC Slab

Precast Components

- Precast Load Bearing Walls

- Precast Non-Bearing Walls

- Precast Staircases & Landing Slabs

- Precast Lift Core Walls

- Precast Bathroom Slabs

- Precast Air-Cond Ledges

In-Situ Typical Floor Slabs

Precast Walls for Roof

Prefabricated Steel Roof Trusses

IBS Score for Seri Jati Part 1 :

Part 1 39.1 / 50

Scoring point :

Use Precast Structural Frames

with in-situ concrete floor using

Reusable System Formwork13

IBS Score for Seri Jati Part 2 & 3:

Part 2 18.8 / 20

Part 3 24.0 / 30

81.9 /100

Scoring point :

Use Precast Walls

Follow MS1064

Vertical & Horizontal Repetition14

IBS Score Advantages- Project has high degree of repetitions for both horizontal and vertical plain.- Architectural and Structural designs with precast intention to capitalise on

precast advantages.- High economy of scale with >900 units apartment with a single unit layout.- Construction logistic is fully considered at planning stage

e.g. wall layout, work sequencing, crane’s capacity and movement.

IBS Score Disadvantages- Brickwork/plastering in stand alone amenities building, box-out for M&E

services/risers and kitchen/yard walls.- Non-compliance in Modular Coordination for structural elements and

architectural design input.

An exciting external facade with different architecture features reduce the

monotonous of the internal repetitive layout.

No columns and projected beams

Consistent squareness

Consistent quality

Steel moulds provide consistent quality

in architecture features

Case Study 2 – Non-ResidentialHospital Kuala Lumpur (SACCHKL)

FLOOR HEIGHT : 9 STOREYS

FLOOR AREA : 600,000 SQ

USAGE : DAY CARE SPECIALIST CENTRE

COME WITH OPERATION THEATRES

: BUILT IN 3 FLOORS OF INTERNAL CARPARKS

OTHERS : SEPARATE M&E BLOCKS

ACCHKL - Method to Achieve 70% IBS Score Requirementa) Columns : Sizes are too heavy for lifting if in precast

components.Cast in-situ using aluminium formwork

b) Beams : Precast components by Setia Precast

c) Slabs : All wet areas are in-situ constructionOther areas used Precast Hollow Core Slabby Eastern Pretech supported by PC Beamsfrom Setia Precast

ACCHKL - Method to Achieve 70% IBS Score Requirementd) Walls : Structural walls used aluminium formwork & other internal and external walls

Lightweight Blocks

e) Staircases : Precast

Part 1

39.2 / 50

Part 2

15.0 / 30

Part 3

16.0 / 20

70.2 /100

IBS Score :

Crane Passage

Internal Crane Passage – Maximise Cranage Radius

Area 1

Area 2

Area 1 : Construction up to Roof Level

Area 2 : Remain void for crane movement while

constructing Area 1.: Construct each bay up to RF

and crane retreat to next bay and repeat sequence.

Area 1

Area 1 Area 1

Area 2

Logistic Planning to resolve proximity of existing buildings and roads

Completed External Facade

Completed Internal Views

Further Enhancement to IBS Score System1. Prefabrication

a) Bathroom Pods/Prefabricated Pre-finished Volumetric Construction (PPVC )

- Truly industrialised system of construction, prefabrication and assembled at factory.

- Eliminate on-site brickworks, plastering, tilings, waterproofing, site wirings and plumbing works and fittings the smallest room with the most number of trades.

- Previous IBS Score (2005) allows a maximum of 1 point at Part 3 Prefabricated Components.

- Proposed to increase IBS points at Part 2 as it comes complete with wall system and finishes.

Further Enhancement to IBS Score System

b) Off-site prefabrication of reinforcement cage for columns, beams and walls

- To consider additional points under previous IBS Score Part 3 (Other labour savingproduct / solution).

2. Elimination of Labour Intensive Process

a) Use of skin walls/cladding to conceal wirings and pipings, instead of traditional hacking and plastering.

- Process is clean and systematic- Good quality finished surface- No hacking of RC walls and brickworks

Further Enhancement to IBS Score System

b) Replacement of brickwalls by using Dry Wall System (including cementitiouspanels and gypsum boards).

- Bricklaying is a labour intensive process- Involved lot of construction logistic in moving bricks, sand, cement, water, mixing

equipment, scaffoldings etc. for work to be executed.- Wet & dirty- Dry wall system is clean, fast, labour efficient and quality is easily control

Where apply as a full replacement for brickwalls, should be incentively considered under previous IBS Score Part 3 (Other labour saving solution).

2005 2010

a) Propose Revision to IBS Score Part 3 2010

- Reinstate 2005 Part 3 Item 3 (Other Prefabricated Component and Labour SavingSolution) to include more prefab structural / finished components e.g.prefab staircases, prefab bathroom unit & unitized building modules.

3. Revision of IBS Score 2010

Conclusion

To target a higher IBS Score :

1) Design shall be modular coordinated, compliance to MS1064 (Utilisation of Standardise Components).

2) Developers & Contractors to plan for the use of IBS from the beginning includingany simplified construction method.

3) Prefabrications where possible.

4) Minimise labour intensive works where possible e.g. brickwork & plastering.

5) Developers should have a preference for IBS construction so that the project sitesare cleaner, less labour intensive and better quality.

6) Contractors should always be looking at more efficient construction methods.

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