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i
THE EFECTIVENESS OF COST AND TIME ON VARIOUS TYPE OF IBS
SYSTEM
GOH TUAN LEONG
UNIVERSITI TEKNOLOGI MALAYSIA
ii
UNIVERSITY TEKNOLOGI MALAYSIA
DECLARATION OF THESIS / UNDERGRADUATE PROJECT PAPER AND COPYRIGHT
Author‟s Full Name: GOH TUAN LEONG
Date of birth : 15TH
FEBUARY 1990
Title EFECTIVENESS OF COST AND TIME ON VARIOUS TYPE OF IBS
SYSTEMS
Academic Session: 2013/2014
I declare that this thesis is classified as:
CONFIDENTIAL (Contains confidential information under the Official Secret
Act 1972)*
RESTRICTED (Contains restricted information as specified by the
Organisation where research was done)*
√ OPEN ACCESS I agree that my thesis to be published as online open access
(full text)
I acknowledged that Universiti Teknologi Malaysia reserves the right as follows:
1. The thesis is the property of Universiti Teknologi Malaysia.
2. The library of Universiti Teknologi Malaysia has the right to make copies
for the purpose of research only.
3. The library has the right to make copies of the thesis for academic exchange.
Certified by:
SIGNATURE SIGNATURE OF SUPERVISOR
900215-03-5213 ASSOCIATE PROFESSOR SR DR ZAKARIA MOHD YUSOF
(NEW IC NO. / PASSPORT NO.) NAME OF SUPERVISOR
Date: Date:
NOTES :*If the thesis is CONFIDENTIAL or RESTRICTED, please attach with the letter from the
organization with period and reasons for confidentiality or restriction.
i
SUPERVISOR’S DECLARATION
“I/We* hereby declare that I/we* have read this thesis and in my/our*
opinion this thesis is sufficient in terms of scope and quality for the
award of the degree of Bachelor in Quantity Surveying (Honours).”
Signature : .........................................................
Name of Supervisor I :ASSC PROF SR DR ZAKARIA
MOHD YUSOF
Date : .........................................................
Signature : .........................................................
Name of Supervisor II : DR NAFISAH BT RAHIMAN
Date : .........................................................
ii
EFFECTIVENESS OF COST AND TIME ON VARIOUS TYPES OF IBS
SYSTEMS
GOH TUAN LEONG
A dissertation submitted in partial fullfillment of the
requirements for the awards of the degree of
Bachelor of Quantity Surveying
Faculty of Build Environment
Universiti Teknologi Malaysia
DECEMBER 2013
iii
DECLARATION
I declare that this thesis entitled “ Effectiveness of Cost and Time For Various Types
of IBS Systems ” is the result of my own research except as cited in the references.
The thesis has not been accepted for any degree and is not concurrently submitted in
candidature of any other degree.
Signature : ....................................................
Name : ....................................................
Date : ....................................................
GOH TUAN LEONG
iv
DEDICATION
To my beloved family and friends.
Thanks for your supports and encouragements
Supervisor and Panels,
Thanks for your guidance and criticism
Thanks for Everything Granted
v
ACKNOWLEDGEMENT
Firstly, I would like to thank my Supervisor, AP SR DR ZAKARIA MOHD
YUSOF for his willingness to share his knowledge and spend out his precious time
to give me guidance, advices and support for me to accomplish this research. I
would also like to thank my lecturers and also to my second reader for giving me
guidance in my research.
Secondly, I would like to thank to my family and friends for their supports
and dedication in helping me to accomplish the research. Besides that, sincere
gratitude is exclusively expressed to Perpustakaan Sultanah Zanariah (PSZ),
Universiti Teknologi Malaysia which had subscribed the international prominent
journals and reading materials to enable me to capture the important information for
the research.
Last but not least, thankful are extended to all my case study respondents for
their cooperation and useful information given. I would like to thank to all my
friends, buddies, course mates who helped me in this research. Thank to you all.
vi
ABSTRACT
Not many among us all except those who are in the midst of progressive
development in the heart of the capital really understood the concepts and
technologies lay behind the Industrialized Building System or simply known as IBS
amongst the construction and build communities. Unrealized, the Government of
Malaysia has put a lot of effort to start the implementation of IBS in their
construction contract and roadmap for IBS toward 2015. Nevertheless, the industry
stakeholders are indifferent of this idea and thus resist toward this change which
probably due to ignorance, perhaps lack of idea and awareness or lack of effort in
understanding the concept and cost in technology transfer due to the initial high cost
in implementation however these technologies enable to reuse for reoccurring
processes. Objectives, this research is to identify the various types of IBS systems
used in our construction industry and evaluate the cost and time of various type of
IBS system, which the result of analysis showed the Precast Framing, Panel and Box
Systems is the most effective IBS system. Case study method has been used as this
research methodology for the research study and descriptive statistics had been used
for analysed the research. Finally the finding result of research shows there are 3
types of IBS systems that are frequently practice in our construction industry. Those
three types of IBS systems are Precast Concrete Framing, Panel and Box Systems,
Steel Formwork Systems and Block Work Systems. The finding of result also shows
the Precast Concrete Framing, Panel and Box Systems is the cheapest and fastest of
IBS and Steel Formwork Systems is the expensive and slowest of IBS.
vii
ABSTRAK
Tidak ramai di kalangan kita semua kecuali mereka yang berada di tengah-
tengah pembangunan progresif di tengah-tengah ibu negara benar-benar memahami
konsep dan teknologi di sebalik Sistem Bangunan Perindustrian atau hanya dikenali
sebagai IBS di kalangan pembinaan dan membina komuniti. Tanpa disedari, kerajaan
Malaysia telah meletakkan banyak usaha untuk memulakan pelaksanaan IBS dalam
kontrak pembinaan dan pelan tindakan untuk IBS ke arah 2015. Walau
bagaimanapun, pemegang kepentingan industri tidak mempedulikan idea ini dan
dengan itu menahan ke arah perubahan ini yang mungkin disebabkan oleh kejahilan ,
mungkin kekurangan idea dan kesedaran atau kekurangan usaha dalam memahami
konsep dan kos dalam pemindahan teknologi kerana kos awalan yang tinggi dalam
pelaksanaan bagaimanapun teknologi ini membolehkan untuk menggunakan semula
untuk proses sering muncul . Objektif kajian ini adalah untuk mengenalpasti pelbagai
jenis sistem IBS yang digunakan dalam industri pembinaan dan menilai kos dan
masa pelbagai untuk pelbagai jenis sistem IBS, di mana hasil analisis menunjukkan
Precast Framing, Panel dan Box Systems adalah sistem IBS yang paling berkesan
dari segi kos dan masa. Kaedah kajian kes telah digunakan sebagai kaedah
penyelidikan ini untuk kajian penyelidikan dan statistik diskriptif telah digunakan
untuk dianalisis penyelidikan. Akhirnya hasil dapatan kajian menunjukkan terdapat 3
jenis sistem IBS yang sering amalan dalam industri pembinaan . Ketiga-tiga jenis
sistem IBS adalah Precast Framing, Panel dan Box Systems, Steel Formwork
Systems dan Block Work Systems. Hasil daripada kajian juga menunjukkan Precast
Concrete Framing , Panel dan Peti Systems adalah yang paling murah dan paling
cepat IBS dan Acuan Keluli Sistem adalah mahal dan paling perlahan dalam IBS.
viii
TABLE OF CONTENT
CHAPTER TITLE PAGE
DECLARATION iii
DEDICATION iv
ACKNOWLEDGEMENT v
ABSTRACT vi
ABSTRAK vii
TABLE OF CONTENT viii
LIST OF TABLE xiii
LIST OF FIGURE xv
LIST OF ABBREVIATION xvii
LIST OF APPENDIX xviii
CHAPTER 1 INTRODUCTION 1
1.1 Background of Study 1
1.2 Issues 3
1.3 Problems Statement 4
1.4 Research Questions 5
1.5 Objective of Study 5
1.6 Significant of Study 5
1.7 Scope of Study 6
1.8 Methodology Research 6
1.9 Organisation Research 8
CHAPTER 2 EFFECTIVENESS OF COST AND TIME FOR THE VARIOUS
TYPE OF IBS SYSTEMS 11
2.1 Introduction 11
2.2 Definition of IBS 12
2.3 Precast Concrete 14
ix
2.4 Pre-Fabrication Technology 15
2.4.1Classification of Pre-Fabrication System 16
2.4.2 Materials 17
2.4.2.1 Wood 17
2.4.2.2 Steel 18
2.4.2.3. Aluminum 18
2.4.2.4. Concrete 19
2.4.2.5. Plastics 19
2.4.2.6 Structural System 20
2.4.2.7 Frame Assembly 20
2.4.2.8 Frame Panels 20
2.4.2.9 Stressed Skin Panels 21
2.4.2.10 Solid Panels 21
2.4.2.11 Poured at Site 22
2.5 Classification of IBS Systems 22
2.5.1 Classification According to Structural System 23
2.5.1.1 Linear System or Frames (beam and column) 23
2.5.1.2 Panel System 24
2.5.1.3 Rectangular or Boxes system or Three Dimensional System
24
2.5.2 Classification According to Material 24
2.5.2.1 Timber 25
2.5.2.2 Bricks and Block Works 25
2.5.2.3 Steel 25
2.5.2.4 Reinforced concrete 25
2.5.3 Classification According to Relative Weight of Components 26
2.6 Characteristics of IBS Systems 27
2.6.1 Essential Characteristics of IBS Systems 29
2.6.1.1 Closed System 29
2.6.2 2Open System 30
2.6.3 Standardisation and Tolerances 31
2.6.4 Specialisation 31
2.6.5 Good Organisation 31
2.6.6 Integration 32
x
2.6.7 Equipment at Site 32
2.7 Type of IBS 32
2.8 Benefits of IBS 36
2.9 IBS Implementation 38
2.10 Promotion of IBS in Malaysia 39
2.11 Roadmap Towards Making IBS A Success In Malaysia 41
2.12 Construction Cost 46
2.13 Cost Control 48
2.13.1 Importance of Cost Control 48
2.14 Time and Duration of Project 49
2.15 Time for Completion 49
2.16 Conclusion 50
CHAPTER 3 RESEARCH METHODOLOGY 52
3.1 Introduction 52
3.2 Research Process And Procedure 52
3.2.1 Identify The Problems and Research Objective 53
3.2.2 Literature Review 53
3.2.3 Data Collection 53
3.2.4 Data Analysis 54
3.2.5 Method of Analysis 54
3.2.6 Conclusion and Recommendation 54
3.3 Research Sampling 55
3.4 Research Instrument 56
3.4.1 Section 1: Project Background 56
3.4.2 Section 2: Types of IBS System Apply by Project 57
3.4.3 Section 3: Cost and Time Information of IBS Project 57
3.5 Data Collection 58
3.6 Data Analysis 58
CHAPTER 4 DATA ANALYSIS 60
4.1 Introduction 60
4.2 Projects Background 61
xi
4.3 Types of IBS Used By The Projects 63
4.3.1 Component of Building Constructed By IBS 65
4.4 Analysis of Cost 66
4.4.1 Total Cost of Projects and Cost / Gross Floor Area 66
4.4.2 Breakdown Cost and Cost /M2 of IBS Project Elements 68
4.4.2.1 Breakdown Cost of Element and Cost / M2 for Steel
Formwork Systems 68
4.4.2.2 Breakdown Cost and Cost / m2 of Element for
Block Work Systems 71
4.4.2.3 Breakdown Cost and Cost / m2 of Element for
Precast Concrete Framing, Panel and Box System. 73
4.4.3 Comparison of Cost / m2 for IBS‟s Projects 76
4.4.3.1 Comparison of Cost / m2 For Steel Formwork 76
4.4.3.2 Comparison of Cost / m2 For Block Work System 78
4.4.3.3 Comparison of Cost / m2 For Precast Concrete
Framing, Panel and Box System 80
4.4.4 Overall Comparison Average Cost / m2 for IBS Project 81
4.5 Analysis of Time 83
4.5.1 Total Time Completion and Comparison of GFA / Time of
Project 83
4.5.1.1 Total Time Completion and Comparison of GFA/
time of Project for Steel Formwork System 84
4.5.1.2 Total Time Completion and Comparison GFA/ time
of Project for Block Works System 86
4.5.1.3 Total Time Completion and Comparison GFA/ time
of Project for Precast Concrete Frame, Panel and Box
System 88
4.5.2 Overall Comparison of Average GFA / Month for
IBS 90
4.6 Conclusion 92
CHAPTER 5 CONCLUSION AND RECOMMENDATION 97
5.1 Introduction 97
xii
5.2 Summary 97
5.3 Problem Facing During The Research 99
5.4 Suggestions and Recommendations 99
REFERENCE 101
xiii
LIST OF TABLE
TABLE NO. TITLE PAGE
Table 2.5.3 IBS systems classification based to relative weight of 27
component.
Table 3.4 Cost of Project for Each Elements 57
Table 4.2 Backgrounds of Nine Projects That Used IBS 61
Table 4.3 The Various Types Of IBS Used By The Nine Projects 64
Table 4.3.1 Component of Building Constructed By IBS 65
Table 4.4.1 Total Cost of Project and Cost / m2 for Nine Projects 67
Table 4.4.2.1 Breakdown Cost of Element and Cost/m2 for Steel
Formwork‟s Project 69
Table 4.4.2.2 Breakdown Cost of Element and Cost/m2 for Block Work
System‟s Projects 71
Table 4.4.2.3 Breakdown Cost of Element and Cost/m2 for Precast Concrete
Framing, Panel and Box System‟s Project 73
Table 4.4.3.1 Comparison Cost/m2 of Element for Steel Formwork‟s Project
76
Table 4.4.3.2 Comparison Cost/m2 of Element for Block Work System‟s
Projects 78
Table 4.4.3.3 Comparison Cost/m2 of Element for Precast Concrete
Framing, Panel and Box System‟s Projects 80
xiv
Table 4.4.4 Overall Average Cost/m2 for All IBS Project 81
Table 4.5.1. Total Time Completion and the GFA/time of Project 83
Table 4.5.1.1 Total Time Completion and GFA/time of Project for Steel
Formwork System 84
Table 4.5.1.2 Total Time Completion and GFA/time of Project for Block
Work System 86
Table 4.5.1.3 Total Time Completion and GFA/time of Project Precast
Concrete Framing, Panel and Box System 88
Table 4.5.2 Average GFA/Month for All Type IBS Project 90
xv
LIST OF FIGURE
FIGURE NO TITLE PAGE
Figure1.8 Flowchart of Organization Research 8
Figure 2.5 Classification of IBS system. 23
Figure 2.7 (I) Precast Concrete Slab 33
Figure 2.7(II) Steel Formwork for Wall 34
Figure 2.7 (III) Steel Frame Structure 35
Figure 2.7 (V) Interlocking Brick System 36
Figure 3.2 Research Flow Chart 55
Figure 4.3 The Various Types of IBS Used By Five Projects 64
Figure 4.4.2.1(a) Breakdown Cost of Elements for Steel Formwork System‟s
Projects 69
Figure 4.4.2.1 (b) Cost / m2 of Element for Steel Formwork System‟s
Projects 70
Figure 4.4.2.2 (a) Breakdown Cost of Elements for Block Work System‟s
Projects 71
Figure 4.4.2.2 (b) Cost / m2 of Block Work System‟s Projects 72
Figure 4.4.2.3 (a) Breakdown Cost of Element for Precast Concrete
Framing, Panel and Box System‟s Projects 74
xvi
Figure 4.4.2.3(b) Cost / m2 of Element for Precast Concrete
Framing, Panel and Box System‟s Projects 75
Figure 4.4.3.1 Comparison Cost/m2 of Element for Steel Formwork‟s
Projects 77
Figure 4.4.3.2 Comparison Cost/m2 of Element for Block Work System‟s
Projects 79
Figure 4.4.3.3 Comparison Cost/m2 of Element for Precast Concrete
Framing, Panel, and Box System‟s Projects 80
Figure 4.4.4 Overall Average Cost/m2 for All IBS Project 82
Figure 4.5.1.1(a) Total Time Completion of Project for Steel Formwork
System 85
Figure 4.5.1.1(b) Comparison of GFA/time for Steel Formwork System‟s
Projects 85
Figure 4.5.1.2 (a) Total Time Completion of Project for Block Work
System 87
Figure 4.5.1.2(b) Comparison GFA/time of Project for Block Work
System 87
Figure 4.5.1.3 (a) Total Time Completion of Project for Precast Concrete
Framing, Panel , and Box System 89
Figure 4.5.1.3(b) Comparison GFA/time of Project for Precast Concrete
Framing, Panel and Box System 89
Figure 4.5.2 Average GFA/Month for All types IBS Project 91
xvii
LIST OF ABBREVIATION
ABBREVIATION FULL NAME
CIDB Construction Industry Development Board
IBS Industrialized Building Systems
GFA Gross Floor Area
WBLFF Work Below Floor Finishes
1
CHAPTER 1
INTRODUCTION
1.1 Background of Study
The concept of Industrialized Building System (IBS) is not new and can be
traced back to as early as 1624 when penalized timber houses were shipped from
England to the new settlements in North America. While steel structures of road
and railway bridges were common in pre-independence Malaya. The IBS is an old
technology in developed country s such as European and American country but it
is considered as the new technology in developing country in Asia region especially
Malaysia (Noorisah Abd Shukor, 2007) .
The IBS system start gain popularity in 1998 when Cabinet of Ministers
endorsed IBS Strategic as the blue print for total industrialisation of construction
sector .( Zanawi, 2009).Soon, The use of pre-cast concrete in the total construction
industry arrived much later when Construction Industry Development Board
Malaysia (CIDB) was promoting the IBS system in 2003. The CIDB has
implemented the IBS Road Map (2003-2010) to encourage and promote more
people using IBS system.
2
The importance of IBS systems was highlighted under the Construction
Industry Master Plan 2006-2015 which is based on 5-M Strategy (Man Powers,
Materials-Components-Machines, Management-Process-Method, Monetary and
Marketing). The purpose of this master plan was to guide the future of Malaysian
construction industry to achieve the Vision of 2020. By applying the IBS system,
it can create situation which lead our construction industry into high productivity
and efficiency. At the same time, it also can contribute the economic benefits to
Malaysian in the future. IBS is far beyond prefabricated solutions and project
implementation. IBS is also about the changing of the conventional mindset,
championing human capital development; developing better cooperation and trust
and most importantly it is high integrity (Sazali Che Amat, 2003).
Despite well documented benefits and strong support from the Government,
the participating of IBS was not high as first anticipated at this stage. Perhaps cost
and time could be the causes of this problem. Although the members of the
industry are open to the idea, but some of major portion of industry stakeholders are
indifferent, perhaps due to resistance towards change and insufficient fund and
information to support the feasibility of change to implement IBS construction. In
November of 2008, the Treasury of Malaysia had warned all the Government
agencies to increase the IBS contents of their building projects to a level of not less
than 70 points of IBS score and IBs must incorporated as part of the contract
document for tender. ( Sazali Che Amat, 2011). Besides that, the private project
also play important role. The private developers need to participate the IBS to
ensuring this program me is successfully implement.
3
1.2 Issues
According to IBS Road Map 2003-2010 (2003), it has been reported only 15%
of overall construction projects in Malaysia used IBS system. IBS Mid Term Review
in 2007 showed only 10% of completed projects used IBS in the year 2006 as
compared to forecasting IBS usage of 50% in 2006 and 70% in year 2008.
The inadequate of IBS manufacturing plant also one of the reason lead to this
issue. There are few IBS manufacturing plant in Northen Penisular Malaysia,
Western Penisular .Malaysia and Borneo Malaysia. The number of plant still very
limited and the location is mostly in Klang Valley. So with limited of plant, some of
the contractor and developer still stick with the conventional method. (IBS Road
Map 2003-2010, 2003),
Instead of that, lacking of IBS knowledge among the developers and
contractors also contributed to this problem, where there are cases that contractor is
using the IBS for construct the building project but in the end, the project delays and
the cost is hiking. This has make the others think that IBS is difficult to adapt and
cannot solve the construction problems.
Many small contractors are reluctant to adopt IBS system and prefer to
continue using the conventional method of construction. This is due to the fact that
small contractors are already familiar with the conventional system and for them the
technology suit well with small scale projects and therefore not willing to switch to
mechanized based system.
In the perspective of components‟ manufacture, IBS construction requires
high initial investment capital for pre-casters to purchase new machinery, mould,
importing foreign technology and wages of skilled workers for installation process
4
(Thanoon et al. 2003). IBS is also unattractive choice due to wide swing of housing
demand, high interest rate and unsure economic condition (Thanoon et al. 2003).
As a result, the industry viewed IBS as threats to their business and not as
opportunities (Noorisah Abd Shukor, 2007). It appears that existing procurement and
contracting system is not „favourable‟ to both pre-caster and contractor which using
IBS method. The inadequate of IBS manufacturing plant also one of the issues that
will not courage them to use the IBS system.
1.3 Problems Statement
Although the IBS system was introduce since two decade ago, but it seems
like still cannot gain very high popularity among the contractors and developers.
From the issues that had been highlighted, it can be summarized that limited
manufacturing plant of IBS caused the project cost increase. Some manufacturing
plants are far away from project location caused the project delay. Insufficient
knowledge about IBS especially the type of IBS and its components to be used on the
project. Without used the appropriate type of IBS and its component on the project
can caused the cost hiking and delayed the project.
To solve these issues, few research questions have come out for this research.
The first question is what types of IBS system provided in our country and the
second question is what is the different cost and time among the various type of IBS
system?
5
1.4 Research Questions
For this research, there are some questions have been identified as follow :
1. What type of IBS systems frequently practice in Malaysia?
2. What are the different cost and time among the various types of IBS
systems for high rise building like apartment and condominium?
1.5 Objective of Study
My objective study will be as follow:
1. To identify the various type of IBS systems used in Malaysia
2. To evaluate the cost and time of the various type of IBS systems for
apartments and condominiums building.
1.6 Significant of Study
From this study, it provides a brief and clear idea to construction
professionals like contractor, Architect, and QS about the effectiveness on cost and
time for the various types of IBS systems. With the information that obtained from
the case study, we can determine how effectiveness cost and time on various types of
IBS systems based on the project Gross Floor Area. From that, construction
6
professionals and other parties that involved can try to determine some ideas,
strategies or solution and some necessary actions to overcome this problem.
1.7 Scope of Study
This study is mainly focus on the effectiveness on cost and time for the
various types of IBS systems. The types of IBS that I targeted are Precast Concrete
Framing, Panel, and Box Systems, Steel Formworks, and Block Work System. The
reason is those three types of IBS are frequently used in our country. My targeted
project is apartment and condominium projects that are used the IBS. There will be
three projects for each type of IBS, the total of projects for my research are nine
projects. More information will be collected through construction journals,
magazines, books and newspapers, articles, and website.
1.8 Methodology Research
There are several methods I‟m using in order to find relevant information to done
this report. Among the methods are:-
Through library sources
Library is a very wide resource for us to search for everything. I often visit the UTM
library, Perpustakaan Sultanah Zainab (PSZ) to look for information and data for my
research. There are many book and journal resources for my references. In library,
7
not only books, magazines, and journals that I can borrow, there are also store the
previous theses that I can refer to look for information.
Through construction magazines and newspapers
I read it every day and concern of what has happen to construction industry
nowadays, what are the problems faced and the solutions done by the government
and private sector. From there, I know what the problems I face and what are
resources or solution to overcome my problems.
Through case study.
Data and information from the books and internets look limited and not enough to
support my research. So the case study will be conducted through selected
contractors firms, developer firms and consultants firms that have involve in any IBS
projects to get more information and data to support my research.
8
1.9 Organisation Research
Figure1.8: Flowchart of Organization Research.
THE EFFECTIVENESS OF COST AND TIME FOR
VARIOUS TYPES OF IBS SYSTEM
Objectives
To compare the cost and time for
the various types of IBS system
To identify the various type of IBS
system
Research Methodology
CASE STUDY
Data Analysis
Conclusion
9
My research will be divided in to five main parts, which are shown below:
Chapter 1: Introduction
This is the first part of my research, it‟s a brief introduction about the title research
will be shown in this chapter.
Chapter 2: Literature Review
In this chapter, it‟s all about the secondary data. Secondary data mean information
and data come from books, magazines, journals, articles, conference, and so on. All
the information are related to the various types of IBS system and comparison cost
and time for various types of IBS system.
Chapter 3: Research Methodology
This chapter will discuss about the method of research. This are included case study
method.
Chapter 4: Data Analysis
In this chapter, data collection from document study will be transform into table,
graph and pie chart. The analysis will be carried out based on the previous data and
also the current statistics.
10
Chapter 5: Conclusion and Recommendation
The last chapter of the research, an overall conclusion will be made after the
finalizing data. Several suggestions will be made in order to improve the current
situations.
CHAPTER 2
EFFECTIVENESS OF COST AND TIME FOR THE VARIOUS TYPE OF IBS
SYSTEMS
2.1 Introduction
The Professional Journal of Surveyors Malaysia, 2008, stated that since
decades ago, the pressure to deliver construction projects at a high speed, lower cost
and high quality has grown. Clients are now virtually demanding that consultants and
contractors deliver the project in half the time as was used to. On a positive note, this
severe level of expectation has accelerated the prominence and implementation of
IBS in the Malaysian construction industry. Nevertheless, the innovative natural of
IBS itself requires a different set of approach and procedures for it to progress and be
substantially attractive to a wider audience. As a result, the need to accurately
estimate the cost of IBS projects has grown more urgent and important. The main
reason is because usually there is no feasible time to re-scope and IBS project since
cost, efficiency and the economies of scale are inseparable determinants. Client and
construction professionals must be cognizant to the cost implication of any design,
specification or scheduling change throughout the entire project development process.
12
2.2 Definition of IBS
According to Nor Azmi et al (2008), IBS is acknowledged in many writings
as a construction method that has many advantages especially on aspects of
construction management. IBS can be defined a system that use industrial production
techniques either in the production of components or assembly of the building, or
both. It is a system where the design and structure of the building are reduced to a set
number of common constituent parts or components, with the rationale that they can
be prefabricated or manufactured in low-term production runs, even far away from
construction site. These components, furnished with standard dimension and
specified attributes, will then be delivered to the site and assembled according to
certain standards in order to bring together the proposed building.
Zuhairi Abd Hamid ( 2012) defined IBS as a construction technique in which
components are manufactured in a controlled environment (on or off-site),
transported, positioned and assembled into a structure with minimal additional site
works. As such, components that are being pre-fabricated in a controlled
environment on-site are also considered as IBS. While there are numerous
descriptions of the Industrialised Building Systems (IBS) concept by local
researchers, all of the definitions stressed on pre-fabrication and mass production.
According to Warswaski (1999), the industrialised building system (IBS) can
be defined in which all building such as wall, slab, beam, column and staircase are
mass produced either in factory or at site factory under strict quality control and
minimal wet site activities. Industrialisation process is an investment in equipment,
facilities and technology with the objective of maximising production output,
minimizing labour resource and improving quality while a building system is defined
as a set 10 of interconnected element that joint together to enable the designated
performance of a building.
13
Warswaski (1999) also explained that an industrialisation process is an
investment in equipment, facilities, and technology with the objective of maximising
production output, minimising labour resource, and improving quality while a
building system is defined as a set of interconnected element that joint together to
enable the designated performance of a building.
IBS also can be defined as construction systems in which components are
manufactured in a factory, on or off site, positioned and assembled into a structure
with minimal additional site works (Shahrul Nizaar Shaari, 2003). The word
„building‟ in the IBS term relates to „constructing‟ and therefore covers all type of
structures, not only for buildings construction. It is a products, system and techniques
used in making construction less labour-oriented, faster than and as well as quality
controlled (Warswaski 1999).
Perhaps the most comprehensive definition of IBS is IBS in the construction
industry includes the industrialised process by which components of a building are
manufactured transported and erected on site and managed to produce lean
construction. The system includes a balanced combination between the software
and hardware components.
The hardware elements are categorised into three major groups which
includes frame system, panel system, and box or modules system. Meanwhile the
software elements include system design, market analysis, development of
standardised components, establishment of manufacturing and assembly layout and
process, allocation of resources and materials and definition of a building designer
conceptual framework (Warswaski 1999).
14
2.3 Precast Concrete
Nor Azmi et al, (2008) has stated the precast reinforced concrete components;
whether fashioned on-site or prefabricated at a distant factory, considered as IBS.
Based on the book of Donald Friedman, (2010), the use of precast reinforced-
concrete units in construction was a logical extension of the use of “off - site
prefabricated” steel, timber, and masonry units. Structure materials were
manufactured, brought to the site, and then installed, as the labors just need to apply
finishing such as plastering and painting. The difference between casting concrete on
site and installing the precast concrete lies in the form of the building in question. A
traditional bearing-wall building could be built substituting precast concrete beams
for wood joist with an increase in strength and safety, since the connection of the
beam to the walls consists of gravity bearing. By contrast, a concrete building meant
to replace a steel skeleton-frame building has to be constructed in a way that replace
a steel skeleton-frame building has to be constructed in a way that replaces the lateral
bracing of the frame, with rigid joints between members or some other form of
bracing.
Both promoters and opponents generally agreed on the advantages and
disadvantages of precast construction, differing only on how important the various
factors were. The advantages include lower costs from moving most skilled labor
from the site to the factory, from a reduced amount of formwork and shoring, and the
ability to perform much of the work during poor weather that would normally halt on
site casting. Another advantage that was not overtly economic was the better quality
control achievable during factory casting. The most serious weakness was the
difficulty in creating rigid and continuous connections between the separate precast
sections. The natural condition of precast sections are as individual pieces designed
to work separately, which is closer to steel construction than cast-in-place reinforced
concrete but without the ability to easily create rigid connections that riveting
allowed in steel. This flaw not only made it difficult for designers to achieve overall
15
stability, but also made the individual sections weaker than the equivalent cast-in-
place sections. (Donald Friedman , 2010).
2.4 Pre-Fabrication Technology
According to Kelly (1951), pre-fabrication can be defined as a modern
method of construction technology that had been introduced in our country for the
past decades ago. Pre-fabrication is a construction method largely rely on
standardized manufactured components in a factory or other manufacturing site.
Once it completed, it will be transporting to the construction site where the structure
is located. This technology is used to be a different characteristic of method of
conventional construction by transporting the materials to the construction site where
all assembly is carried out.
Since our country construction industry growth rapidly, it become clear that
how important the uses of pre-fabrication to influence the developers and contractors.
This term bring so much effect to the design of building as the marketing sales and
financing increasing upon the good design. Therefore, the prefabricators will bring in
more expert staff or retain the service and management in order to deal with the
problem that will face in the future. The theory behind this technology is time and
cost can be saved if similar construction tasks or projects be grouped together,
and same technique and method can be employed in prefabrication at a location
where skilled labour is available, while spending long time casting in-situ on site can
be reduced. Prefabrication avoids the necessary of many skilled workers at the
construction site, and other limitation condition such as a lack of power, lack of
material, or exposure to extreme weather are avoided (Kelly, 1951).
16
2.4.1Classification of Pre-Fabrication System
Generally, there are two most popular basis of classification can be
categorized in pre-fabrication system, by materials and by structural system (Kelly,
1951).
Materials Structural System
Figure 2.4: The Classification of Pre-fabrication System.
Classification of Pre-fabrication System
Frame
Steel
Aluminum
Concrete
Plastics
Wood
Frame Panel
Stressed Skin
Panels
Solid Panels
Poured at Site
17
2.4.2 Materials
Materials play a very important role in choices and adaptability to the
prefabricator‟s pattern of operations and for customers or clients satisfaction and
requirements. Most of the special quality required by clients in materials make by
prefabricators being light weight, strength, wearing quality, adaptability to normal
fabrication and transportation methods, and low cost as well. There are four types of
material that usually used by prefabricators, wood, steel, aluminum, concrete and
plastics. (Kelly, 1951),
2.4.2.1 Wood
Nowadays, wood can be categorized as one of most important structural
material in construction industry and also used by largest group of prefabricators.
The type of the wood usually used by most of the construction is plywood whereby it
brings a large influence on the growth of prefabrication as a whole. This material is
very light and strong, extreme stiff, has some insulation value, comes in large sheets
readily adapted to mass-production uses, has fairly good dimensional stability, and is
reasonably durable and low in cost. Plywood has some several functions can be
combined. Example, a single sheet can be both surface and structural sheathing on
the outside, or both surface and wallboard on the inside (Kelly, 1951).
18
2.4.2.2 Steel
Steel is considered as a basic manufacturing material in our country
construction industry. Most of the time, the steel is used for manufacture of low cost
housing. Prefabricators normally used steel as a basic material in their structure.
With this, they used steel in combination with wood and aluminum. Steel still has
some disadvantages in housing design. Its thermal conductivity is more than 300
times of wood so that more attention must to be paid to problem heat loss and
condensation. Steel easily get rust so it must be carefully protected from contact with
oxidizing atmospheres and this automatically increase the cost (Kelly, 1951).
2.4.2.3. Aluminum
Aluminum is one of the major structural materials. It can be form as framing
or exterior structural covering. Many prefabricators are interested of it because it is
easy to get and most importantly the price is cheap compare to steel and wood.
Aluminum has certain advantages for housing purposes, including a positive value as
reflective insulation and a strong resistance to serious corrosion under normal
atmospheric conditions. Aluminum is suited to many construction industry
techniques although it can be welded only with some difficulty and must be formed
with careful attention to its properties (Kelly, 1951).
19
2.4.2.4. Concrete
Sometime, prefabricators consider wet-process materials unsuited to
mass production methods, although there are exceptions, as when such special
fabrication machines are introduced. Yet, there are still many companies still using
concrete to form precast concrete slabs. Concrete may have distinct advantage over
other materials in original materials cost, but its disadvantages of weight, bulk, and
frangibility have limited its use primarily to group erections close to the production
points of the slabs (Kelly, 1951). Pre-stressed concrete shows promise of achieving
two or three times the strength of ordinary concrete with the same weight of material
and its being more generally used in the construction industry, but all these still
concern by prefabricators.
2.4.2.5. Plastics
Plastics are an ordinary material in construction industry. However, it was
doubt by prefabricators to use as a major structural material. In part, this was
undoubtedly the result of the high cost of most plastics, now and in the foreseeable
future, but there is also evidence that the structural properties of most plastics are
inferior to those of wood, steel, concrete and aluminum. Laminated phenolics, the
most seriously considered of the plastics as a structural material, have three or four
times greater strength in compression than in tension, which make it difficult to
justify using so expensive material in tension as a working skin. The plastics industry
is at work on these problems, and such new materials as glass fiber reinforced show
promise (Kelly, 1951).The major structural use for plastics, however, remains in the
bonding of plywood and other built-up structural materials.
20
2.4.2.6 Structural System
In building construction, the structural system is most important major
element so that it can support and transmit applied loads safely to the ground without
exceeding the allowable stresses in the members. Basic types of systems
include bearing-wall, post-and-beam, frame, membrane, and suspension. For the
frame, it can be sub-divided into five types, Frame Assembly, Frame Panels, Stressed
Skin Panels, Solid Panels and Poured at Site.
2.4.2.7 Frame Assembly
The typical frame assembly is the conventional wood frame house, in the
course of construction of which individual framing members are erected at the site
and various insulting and finishing materials then applied. The precut lumber house
is an example of a fabrication system embodying frame assembly principles (Kelly,
1951).
2.4.2.8 Frame Panels
In this classification, the structural members are preassembled in the form of
panels, and some or all of the insulting and finishing materials are usually applied in
the shop in order to save time at the site. The wall panel produced by what may be
called the typical prefabricator is a frame panel, made up of framing lumber with
wood sheathing nailed to it.
21
2.4.2.9 Stressed Skin Panels
According to Kelly, (1951), where the panels are so designed and assembled
that the surfacing elements contribute in a major way to the structural performance of
the whole, it‟s called as a stressed skin panel. A stressed skin action is partially
obtained by the use of a single surface material bonded securely to the structural
framing and by this means developing some stiffness and strength at the contiguous
surfaces. Most of the construction having single factory-applied surface are not
securely enough bonded to develop this added strength. There have been some
attempts to approach a monocoque system of construction, but requirements for
opening and difficulties with single pre-stressed shell. Stressed skin design used to
reduce the amount and weight of materials. It has a better chance to adapt well to
mass-production industrial processes.
2.4.2.10 Solid Panels
The example for solid panel is the precast concrete slab, which is essentially
homogeneous throughout. There are reinforce steel and laminated panels with
plywood or asbestos cement facings involved, where major structural resistance to
load is channeled into skin or reinforcement, the panels should perhaps logically be
place under other structural system. But where the panel is fabricated as a solid entity
(excluding honeycomb core materials), and where all parts of the panel assume major
structural roles, the designation of solid panels has been used (Kelly, 1951).
22
2.4.2.11 Poured at Site
Kelly,(1951) has stated this system includes essentially monolithic structures
in which the emphasis in the pre-fabrication system tends to fall as much upon the
pouring and forming machinery as upon the house itself. This system specially
designed to make concrete pouring and forming operations at the site efficient and
economical, have recently been regarded with a great deal of interest of interest in
this country. A factor in this interest has been the recent rapid expansion of the
development of lightweight concretes, offering easier handling, better surface
qualities, far better thermal properties, and a faster casting cycle than the regular
concretes, while retaining sufficient strength to be self-supporting and avoid the
necessity of added framing or skins.
2.5 Classification of IBS Systems
According to Warszwazaki, (1999), the IBS systems can be classified into 3 main
aspects :
I. Classification according to structural system.
II. Classification according to material.
III. Classification according to relative weight of component.
23
Figure 2.5 :Classification of IBS system.
2.5.1 Classification According to Structural System
Based on Warszwazaki (1999), there are three categories IBS can be
classified in this structural system aspect. There are:
I. Linear system or frames (beams and column)
II. Panel System
III. Rectangular or Boxes system or Three dimensional system
2.5.1.1 Linear System or Frames (beam and column)
CLASSIFICATION OF IBS SYSTEMS
Structural System Relative Weight of
Component
Material
24
According to Warszwazaki (1999), linear system or frame is system that use
column and beam as the main structure member where columns and beams support
all the building weight. The walls need to be light and easy to be installed and
concrete panels are introduced as flooring element.
2.5.1.2 Panel System
In the opinion of Warszwazaki (1999), the panel system is the most widely
used types of prefabricated system those employing panel-shaped elements for floor
slabs, vertical support, partition, and exterior walls. This system maybe prefabricated
with a considerable amount of finish work – exterior finish, thermal insulation,
electrical conduits, window, frame and others. Most of this system often used in
residential building, for example: office, schools, hotels and other similar buildings
with moderate loads and large amounts of finish works.
2.5.1.3 Rectangular or Boxes system or Three Dimensional System
This boxes system functioned as the main building elements, it is a box unit
that contain concrete walls and floors. The unit can be either cast in box like molds
or assembled in the plan from panel elements. In both cases, they can contain a
substantial amount of finish works – walls and floor finish, electrical wiring an
fixtures, painted and glazed doors and window, plumbing pipes and fixtures and so
on.
2.5.2 Classification According to Material
25
The materials classification for IBS systems can be categorized four types,
timber, bricks and block works, steel, and reinforce concrete.( Jaspal Azam et al,
2009)
2.5.2.1 Timber
There are two types of prefabrication of timber which is ready-cut plus shop
fabrication of joints (column and beam) and structural panels where there are only
walls and floors without column and beam.
2.5.2.2 Bricks and Block Works
The bricks or blocks are manufactured and carried out in a mass at factory
and transported to site or onsite of the building under construction in the form of
panel and then erected Warszwazaki (1999).
2.5.2.3 Steel
Steel construction normally contains factors of prefabrication which is one of
the criteria of IBS. Steel is an element jointed by welding, riveting or bolting on site.
The large proportion of the strength from steels capable to support the weight of
structure building and allows a long-span or high-rise building (Warszwazaki ,1999).
2.5.2.4 Reinforced concrete
26
Reinforced concrete has high degree of availability, low material cost,
durability, and fire resistance. In reinforced concrete, the tensile strength of steel and
the compressive strength of concrete work together to allow the member to sustain
these stresses over considerable spans.(Warszwazaki ,1999).
2.5.3 Classification According to Relative Weight of Components
The IBS components can be classified according to their relative weight as in
Table 1. According to Thanoon cited Majzub, (1977), the relative weight of
components should be used as a basis for building classification due to the factor of
weight has significant impact on the transportability of components and has influence
on the production method of the components and their erection method on site.
27
Table 2.5: IBS systems classification based to relative weight of component. ( Thanoon cited
Mazjub, 1997).
2.6 Characteristics of IBS Systems
According to (Warszawski, 1999), The main features of an industrialised
building system are as follows:
No. General System Systems Production Materials
1. Frame System Light weight frame Wood, light gage metals.
Medium light weight frame Metal, reinforce plastics, laminated wood.
Heavy weight frame Heavy steel, concrete.
2.
Panel System
Light and medium weight
panel
Wood frame, metal frame, and composite
materials.
Heavy weight panel (factory
manufactured)
Concrete.
Heavy weight panel (tilt up –
produced on site)
Concrete.
3.
Box System
(modules)
Medium weight box (mobile) Wood frame, light gage metals,
composite.
Medium weight box
(sectional)
Wood frame, light gage metals,
composite.
Heavy weight box (factory
manufactured)
Concrete.
Heavy weight box (tunnel
produced on site)
Concrete.
28
i. As many of the building elements are prefabricated offsite, at a central facility,
where specialized equipment and organization can be established for this purpose.
ii. The various building works are incorporated into large prefabricated assemblieswi
th minimum erection, jointing and finishing work onsite.
iii. Materials and component handling onsite is extensively mechanized; in concrete
work, large standard steel forms, ready-mixed concrete, and concrete pumps are used.
iv. Design, production, and erection onsite are strongly interrelated. They must bevie
wed therefore as parts of an integrated process which has to be planned and
coordinated accordingly.
Industrialised Building System has its own characteristics which are differ
itself from convention method. There are characteristics of Industrialized Building
System are (CIDB, 2001):
i. Industrial production of components though prefabrication; or highly mechanized
in-situ processes
ii. Reduced labour during prefabrication of components and site works.
iii.Modern design and manufacturing methods which has the involvement of
Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM).
iv. Systematic Quality Control such as ISO 9000 principles.
29
v. Open Building concept where it is permitting hybrid applications, adaptable to
standardization and Modular Coordination (MC).
2.6.1 Essential Characteristics of IBS Systems
There are some necessary characteristics underlining the successful
implementation of industrialised building system. The characteristics are briefly
explained at below.
2.6.1.1 Closed System
According to (Warszawski,1999), a closed system can be classified into two
categories, namely production based on client‟s design and production based on pre-
caster‟s design. The first category is designed to meet a spatial requirement of 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 pre-
caster is always forced to produce a specific component for a building. On the other
hand, the production based on pre-caster‟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 incur due to the specific design.
30
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 pre-caster to enlighten the clients and
designer the potential benefit of the system in term of economics and noneconomic
aspects.
2.6.2 2Open 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 pre-caster has been proposed. This system is plausible because it allow
the pre-caster to produce a limited number of elements with a predetermined range of
product and at the same time maintaining architectural aesthetic value. ( Thannon
cited Trikha,1999)
Based on ( Thannon cited Trikha,1999), 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.
31
2.6.3 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
( Thanoon cited Trikha,1999).
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 (Thanoon, 2003).
2.6.4 Specialisation
According to (Warszawski, 1999), 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 number of small
homogenous tasks. In such working condition, workers are exposed to their work
repetitiously with higher productivity level.
2.6.5 Good Organisation
High production volume, specialisation of work, and centralisation of
production requires a efficient and experiences organisation capable of a high level
32
of planning, organising, coordination and control function with respect to production
and distribution of the products (Warszawski, 1999).
2.6.6 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 (Warszawski, 1999).
2.6.7 Equipment at Site
For the purpose of erecting and assembling precast panels into their position,
heavy crane is required especially for multi-storey building. It is therefore important
to incorporate this additional cost when adopting a prefabrication system
(Warszawski, 1999).
2.7 Type of IBS
According to CIDB, IBS Centre, (2003), Industrialised Building System (IBS)
is a technique of construction whereby components are manufactured in a controlled
environment, either at site or off site, and transported, positioned and assembled into
construction works. There are five main IBS groups identified in Malaysia, there are:
33
I. Precast Concrete Framing, Panel and Box Systems
Precast concrete elements are the most common IBS type.
There are precast concrete columns, beams, slabs, walls, lightweight
precast concrete, and permanent concrete formworks. Beside, it is also
consist of 3D components such as balconies, staircases ,toilets, lift
chamber, refuse chambers and others.
Figure 2.7 (I) : Precast Concrete Slab (CIDB,2010)
II. Steel Formwork Systems
This system generally involved site casting, and therefore
subjected to structural quality control. So, it is considered as the “low
level” or the “least prefabrication” IBS types. However, this system
does offer high quality finishes and fast construction with less site
34
labour and material requirement. These include tunnel forms, tilt-up
systems, beam and columns moulding forms and permanent steel
formworks like metal decks.
Figure 2.7 (II): Steel Formwork For Wall (CIDB,2010)
III. Steel Framing Systems
This system commonly used with precast concrete slabs, steel
columns and beams have always been the popular choice and used
extensively in the fast-track construction of skyscrapers. Recent
development in this type of IBS includes the increased usage of light
steel trusses. It is consisting of cost-effective profiled cold-formed
channels and steel portal frame systems as alternatives to the heavier
traditional hot-rolled sections.
35
Figure 2.7 (III) : Steel Frame Structure (CIDB,2010)
IV. Timber Framing Systems
This system is including timber building frame and timber roof
truss. While timber roof truss systems are more popular, timber building
frame systems also have its own niche market where it is offering
interesting designs from simple dwelling units to buildings requiring high
aesthetical values such as chalets for resorts.
V. Blockwork Systems
This system includes interlocking concrete masonry and
lightweight concrete blocks.
36
Figure 2.7 (V) : Interlocking Brick System (CIDB,2010)
2.8 Benefits of IBS
Kamarul, Ghani, Charles Egbu & Mohammed Arif, (2010) had mentioned
there are several aspects of IBS that has the potential of contributing benefits to
construction industry Some of the major aspects are explained below:
i. Sustainability from Controlled Production Environment
IBS offers a controlled manufacturing environment with the ability to reach
difficult nooks and corners, which are often inaccessible in regular in-situ
construction. With the availability of production tools, and permanent jigs and
fixtures, it is easier to control the workmanship of construction, ensuring a tighter
construction resulting in lot lesser energy loss due to leakages (thermal leakage).
37
ii. IBS and Waste
IBS traditionally has been known to minimize waste, with the ability to reuse
material from one module or product into another, the sustainability agenda is
supported through its use. However, several aspects of planning both in terms of
materials management and production management have to be monitored in order to
achieve the waste minimization benefits promised by IBS.
iii. IBS and Building Materials
Several pre-fabricated technologies such as Structural Insulated Panels (SIPS)
offer great potential in terms of fabrication of more energy efficient buildings [18].
However, if appropriate process control and planning are not implemented these
potential benefits could be lost due to expensive on-site assembly processes.
Therefore, it is important that the advent of new technologies should be accompanied
by proper process design for on-site assembly.
iv. IBS and Logistics
Some estimates recently have put the amount of environmental impact from
material transportation activities to be one-third of total environmental impact on the
entire construction process. IBS offers another benefit, and that is the ability to order
in large quantities thus reducing the number of trips to be taken. Despite this
potential benefit, it is important that a detailed material transportation and logistics
plan be put in place.
38
v. IBS and Economic Sustainability
With Malaysian government‟s emphasis on reduction of reliance on foreign
labour, and the ability of IBS to deliver to this goal is well documented. However,
for this to succeed there is the need to develop a detailed training and dissemination
strategy for promoting IBS and preparing the workforce for that.
2.9 IBS Implementation
According to Zawawi,(2009), Implementation stage caries largest scale of
project life cycle including variety of physical work such as design, fabrication work
at factory, logistics task (example: transportation, supply chain management, vendor),
installation and erection work at site, and commissioning.
In the other words, there are several activities of implementation which can
be categorized as upstream activities and downstream activities. Upstream activities
can be list as design, planning and production works. On the other hand, procurement
system, supply chain, transportation system, legislation and regulation can be
classified as downstream activities in implementing IBS. Different activities of a
project can proceed subsequently with different speeds in design and consequent
stages, but all must come together in testing and commission stage for the finish
building.( Zanawi et al, 2009)
39
2.10 Promotion of IBS in Malaysia
According to Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and
C.M Tham, (2001), Construction Industry Development Board of Malaysia
(CIDB),Kementerian Perumahan dan Kerajaan Tempatan (KPKT), and the Public
Institution of Higher Learning (IPTA) are currently championing the IBS promotion.
To achieve this, a concept of coordination of dimension and space in which buildings
and components are dimensioned and positioned in terms of basic unit or module is
being introduced and known as Modular Co-ordination (MC). The introduction of
MC in the industry is to improve productivity and quality in building as well as to act
as a tool towards rationalization and industrialization of the building industry.
MC provides a practical approach towards achieving the following objectives
( Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001):
I. The establishment adoption of a dimensional system agreeable to all
parties;
II. Rationalisation of traditional or conventional approach in building design;
III. To promote the development towards an open building system; and
IV. To facilitate the development of a cataloguing system for building
components.
CIDB together with KPKT and IPTA have developed a number of
strategies for the effective introduction and implementation of MC in the
industry. Every player in the industry would have roles to play to help the MC
be successfully implemented. (Salihuddin Radin Sumadi , Johnson W.K. Ng,
S.L. Sim and C.M Tham, 2001).
40
Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M
Tham, (2001) also mentioned CIDB has designed a series of courses with the
objectives of training and exposing the participants to the basics of MC.
Advanced MC courses have been designed for those who presently submit
drawings to the local authorities. These courses would provide opportunities
for the submitting person to be registered by CIDB as a qualified person in MC
and thus, given permission to use MC mark in their drawings.
To professionally execute these courses, CIDB has collaborated with
a numbers of professional institutions and industrial associations. They will
provide the facilities and infrastructures for the courses. Further training
options and services offer would be made known to their target audience.
(Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001)
Strategies for the implementation of MC were formulated as follows
(Salihuddin Radin Sumadi , Johnson W.K. Ng, S.L. Sim and C.M Tham, 2001):
a) Promotion of building components that conforms to MS 1064 through
MC Certification Scheme,
b) Enforcement through Uniform Building by-laws by Local Authorities;
c) Provide intensive training to all players of the construction industry,
especially those directly involved in the MC, e.g. Submitting Person,
manufacturer, contractor, and others.
d) Promotion of MC to all relevant parties in the industry, and
e) Implementation of MC pilot projects.
41
Meanwhile, CIDB through Construction Research Institute of
Malaysia (CREAM) is set to be the center for information on R&D for the
construction sector. This service ensures that information gathered by CREAM
is delivered or available for the construction industry. Promotion of research
products through publication in scientific journals, CREAM journals, bulletin
or report will be useful industry resource. (Salihuddin Radin Sumadi , Johnson
W.K. Ng, S.L. Sim and C.M Tham, 2001)
2.11 Roadmap Towards Making IBS A Success In Malaysia
Instead of identified the barriers to the introduction of IBS in the
country, Salihuddin Radin Sumadi , Johnson W.K. Ng and Salman Ullah
Sheikh, (2003) have suggest some measures, which would facilitate adoption
of IBS in the country. The following measures are discussed below (Salihuddin
Radin Sumadi , Johnson W.K. Ng and Salman Ullah Sheikh, 2003):
I. Implementation of Modular Coordination (MC)
Dimensional rules for manufacturing of modular parts of all kinds are
the key to a higher productivity of the construction industry, hence, reduced
costs. Modular coordination is about efficiency in industrial production to
coincide with high activities in the building industry and reduced wastage.
Hence, it would definitely reduce the cost of construction by a big margin. This
in the end will benefit the end users, especially houses buyers, enabling them to
purchase property at a relatively cheaper cost and with higher quality of
workmanship.
42
II. Policies
Policies should be drafted in ways which will encourage the use of
IBS in the local construction scene.
a) State Intervention and Stipulations
The government needs to recognize the advantages, which accrue
from adoption of IBS. These not only improve the speed of construction,
hence it can meeting the targets of house construction as made out in its
national plans, affordability, quality of construction which assures a life
span of at least 50-60 years, indoor comfort, and social acceptability. To
gain these advantages, it is very important for government proclaim the IBS
to be the common practice for building construction.
b) Reconstructing of The Building Industry
The building industry ought to do the same and restructure itself into
conglomerates and giant players to be able to undertake mega projects without
the assistance of foreign consultants. It will become immediately clear to the
reconstructed industry that conventional building practices, which are short on
technology and heavy on labor, must be abandoned, and that innovations in
materials, building components and building systems are ultimately more suited
in the charged scenario. It will be easily realized that capital investment in
automation in production of elements and in erection will pay ultimately
dividends which are beyond expectations. Such restructuring will not obliterate
the need for small players but these small players will be undergoing a radical
43
wholesome transformation to fit in with the requirements of mega projects and
the big industry players.
c) Manufacturing Facilities For Prefab Components
The MC dimensioning would permit standardization of building
components with permitted tolerance for manufacture. Different options for
prefab elements would emerge for different building systems. Thus for frame
construction, prefab beams and for different story construction, prefab columns
of different heights with integrated brackets would be required. In panel
construction, possibilities of prefab solid or sandwich panels exist. The panels
could be full sized or only partial, with or without openings. Precast mortar less
elements using interlocking blocks could be devised. Precast parts for roof
trusses could be become assemblies for the complete roofs. Full sized slabs or
precast RC planks, which could be handled manually, would make the floors.
In order to cater the enormous demand created for prefab elements of
different types and cost and labor saving measures, manufacturing industries
would have to resort to automation in production and manufacturer of
elements. The financial institutions and the government policies are thus
needed to provide for the initial capital investment in setting up such
industries and import of appropriate machinery.
44
III. Research and Development (R&D)
R&D is a must in the construction industry even though many
perceive the industry to be a matured industry, which is incapable of
utilizing new ideas and technology.
a) Information and Dissemination
It is estimated that is the last 5 years, 10% or about RM 10 billion
have been lost in construction industry due to poor information management
amongst the industry players like suppliers, contractors, architects and
designers. The Information Management & Dissemination System (IM&DS)
will be a special purpose software controlling and dissemination mechanism
coordinating all construction aspects like material procurement sources,
component manufacturers, standard prefab elements, standards architectural
plans for DIY house construction, cost analysis and instructions for self-help
construction. The system will be accessible through internet to potential users.
Mega corporations could have additional modules to include tendering process,
sales and loan schemes, maintenance schedules and the like. Such elaborate
IM&DS will play a crucial role in propagating the use of IBS on a vast scale in
the country.
b) Industry R&D Linkages
No imported IBS can cater to the socio-economic constraints of individual
countries. This is especially true in case of west originated IBS, as there are vast
45
differences in social and cultural values and in climate and ground conditions. There
is thus a great compulsion for indigenization of imported IBS and the development of
indigenous IBS is justified for more than just economic considerations. This is
possible only if strong linkages between industry and research centers are created. As
today, research centers can only provide basic scientific back up and novel ideas of
innovations in materials and components. Prototyping the laboratory ideas into pilot
production and viable erection and assembly procedures require not only
considerable financial inputs which are beyond the capacity of the research centers
but also require a constant evolutionary approach synergizing with the vast
experience of the building industry.
c) Benchmarking
A benchmarked practice needs to be established for performance
measurement. Increasingly, the major clients are seeking assurances from
contracting organisations that they are using a process of continuous
improvement within their company. Clients normally seeking long term
partnership contractors to assured the project performance and quality. Similar
requirements also form an important feature of many quality management
systems. The benchmarking initiative can provide a major role in delivering
these requirements in an objective manner.
IV. Human Resource
By having a comprehensive training and accreditation system in place,
our erectors, fabricators, installers and supervisors can be trained in the various
aspect of modular construction such as handling, erection, jointing and safety
procedures. On a similar note, our engineers and architects can also be trained to
handle this technology by introducing IBS syllabus in the institutions of higher
learning (IPT). Our present syllabus, for an example concentrates heavily on in-situ
46
construction, with only marginal attention towards construction involving
prestressed , precast or prefabricated elements. A paradigm shift can also be
brought about in the thinking of practicing engineers and architects by encouraging
the Institute of Engineers (IEM) and Association of Architects (PAM) to have more
seminars and talks on the merits of modular construction.
V. Construction Management
From construction manager‟s point of view, the contract document,
the conditions of contract and the tender document should be drafted in such a way
that emphasizes and facilitates or at least allows the use of modular construction.
Plans and drawings using this type of construction should obtain speedy approval
from various bodies such as the Municipal Council and Fire Department.
2.12 Construction Cost
Dobson (2004), has mentioned the construction cost is one of the
hardest element in project management. Cost can be divided into seven parts or
components in a project construction, the seven of cost components are
(E.Haynes,1992):
I. Labor – The wages paid to all staff directly working on the project for
the time spent on it.
47
II. Overhead – The cost of payroll taxes and fringe benefits for everyone
directly working on the project for the time spent on it. Usually
calculated as a percentage of direct labor cost.
III. Materials – The cost of item purchased for use in the project. Includes
such things as lumber, cement, steel, nails, screws, rivets, bolts, and
paint.
IV. Supplies – The cost of tools, equipment, office supplies, etc., needed for
the project. If something has a useful life beyond the project, its cost
should be prorated.
V. Equipment rental – The cost of renting equipment such as scaffolding,
compressors, cranes, bulldozers, trucks, etc., for use on the project.
VI. General and Administrative – The cost of management and support
services such as purchasing, accounting, secretarial, etc., for time
dedicated to the project. Usually calculated as a percentage of project
cost.
VII. Profit – In a for-profit project, the reward to the firm for successfully
completing the project. Usually calculated as a percentage of project
cost.
Project management is directly managed and control expenses and the cost
involved. Application of IBS will save labor costs compared to the conventional
method. Intensive mechanical equipment and minimal use of skilled labor can reduce
48
30-40 percent of the cost of the work. Instead of reduce the uses of timber formwork
and the reinforcement steel, IBS also directly minimize the waste costs at site.
(Trikha dan Abang Abdullah, 2004)
2.13 Cost Control
The purpose of cost control are (Kerzner H,2003) :
I. Limitation provisions provided by the client.
II. Produce a design that fits the existing provisions
III. The concept of money for value, value engineering and buildability to get
optimal cost for a project.
2.13.1 Importance of Cost Control
Ashworth A. (2004), stated the importance of cost control are:
I. That the provision is not lost and exceeds the original amount.
II. To control design changes and scope of the planned project early.
III. Maximize profit margins for the contractor.
IV. Control of the waste material and double handing works.
49
2.14 Time and Duration of Project
Time in the context of the construction industry can be described as referring
to the time involved during the process of development through construction
activities. Project is unique, one of the characteristics of the project is start and end
time. For completion time should be emphasized during construction activities.
Generally, the work activities can be made by scheduling or programs with data
detailing work such as critical path method (CPM), Ghant cart, PERT and others
(Brian Cooke and Peter William., 2009). Trikha dan Abang Abdullah (2004) stated
the completion of time by using the IBS method is 70% faster than conventional
method. Short period of time driven by IBS panel system installation is simple and
quick with the use of machinery mechanisms (Modul Pengurusan System IBS CIDB,
2010).
2.15 Time for Completion
Most standard condition of contract has similar provisions as regards time
completion and somewhere in the contract will be stated (Brian Cooke and Peter
William, 2009):
Date for possession of the site.
Date(s) for possession of specific sections of the site. (where appropriate)
Date for completion of the works.
Date(s) for completion section(s) of the works.
50
Time periods for deferment of possession may also be stated so that the
employer may delay handling over the site to the contractor without breaching the
contract. The contract will usually state the agreed rate of liquidated and ascertained
damages (LAD) for the whole, or where applicable, sections of the works, so that the
employer may charge the contractor in the event of late completion of contract (Brian
Cooke and Peter William, 2009).
2.16 Conclusion
Industrialized Building Systems (IBS) or off-site construction has been
introduced to cope with a growing demand of affordable housing, solving issues
associated with foreign workers and improving image, quality and productivity of
construction related services in Malaysia. IBS can be a strategic move for the local
construction industry to further up the value chain, transforming it into a service
industry that deals with components manufactured in factories.
CHAPTER 3
RESEARCH METHODOLOGY
3.1 Introduction
Research methodology is a method that could be applied to get the data and
information in the research that will be conducted. In the other word, it is defined as
a methodological process to search, collect, identify, and valuation the data for
analysis purpose. This may need a proper plan, systematic, and good understanding
before conduct the research. Thus, the research methodology is important for this
research to achieve the objective and purpose of this study.
3.2 Research Process And Procedure
This research can be divided into five stages, 1) Identify the problems and
research objective, 2) Literature review, 3) Data collection, 4) Data analysis and 5)
Conclusion and recommendation.
53
3.2.1 Identify The Problems and Research Objective
This is the first stage of beginning of the research, whereby I need to find out
the problems and issues based on some reading and understanding towards the
articles, newspapers and journals about the effectiveness on cost and time for various
types of IBS issues. Then, I determined the research question based on my problem
statements and formulated and developed it as questionnaire and interview questions
on my research methodology.
3.2.2 Literature Review
The main purpose of literature review is to collect more information from this
secondary data. The secondary data mean the data or information about various types
of IBS systems that can obtain from books, articles, magazines, journals, some
electronic source like internet, e-books, and websites. Most of this source can be
found at UTM and Built Environment Faculty library. With more information and
data, it can make me more understand my research objective.
3.2.3 Data Collection
Data collection can be collected from two sources, primary data and
secondary data. Primary data can obtain from case study. For this research, a study
has been conducted on contract documents of nine same types of project from
different companies. The documents are Bill of Quantities (BQ) of the project that
contains the cost of project and the time completion of project. The secondary data is
based on the literature review in chapter 2.
54
3.2.4 Data Analysis
This part is the most important part in the research whereby analysis on the
research based on appropriate statistical method from the data collection. For the
case study, documents in the form of oral and writing can become one of the best
research data. Therefore, a case study is conducted on contract document and
architectural drawings to abstract out the data. It can provide important information
and data about the study subject experience that will be very useful for this research.
3.2.5 Method of Analysis
The method of analysis that used for this research is Descriptive Statistics.
This method used to describe the basic features of the data in a study. This method
can provide simple summaries about the sample and the measures. Together with
simple graphics analysis, it can form the basis of virtually every quantitative analysis
of data.
3.2.6 Conclusion and Recommendation
After the analysis of data, a conclusion on the finding will be made for this
research to identify the various types of IBS systems and comparison of the cost and
time for the various types of IBS system.
55
Figure 3.2 Research Flow Chart
3.3 Research Sampling
The term „sample‟ means a specimen or part of whole (population) which is
drawn to show what the rest is like. Research sampling is something that used and
chooses to collect data for our purposed of the study.
Base on this research, the research sampling that has been use for the study
are contract documents and Architecture drawings based on different type of IBS
systems. The BQ and architecture drawings can obtain from contractor firms and
Problems Statement
Identify Objectives
Literature Review
Data Collection
Primary Data Secondary Data
Data Analysis
Conclusion & Recommendation
Stage 1
Stage 2
Stage 3
Stage 4
Stage 5
56
developer firms that have been involved in any IBS project. Nine completed projects
that consist of various type of IBS system had been obtained .and will be undergoing
analysis process to abstract the data.
3.4 Research Instrument
The research instrument for this research is conducted document analysis on
the contract documents to get the project and its element cost. The document analysis
also conducted on architecture drawing to get the project gross floor area. Because
the contract documents and the architecture drawings are private and confidential,
hence a document analysis form has been designed in order to abstract the data out
from the contract documents and drawings that has been study.
The way to design a relevant survey form is very important in order to obtain
the intended and adequate information from those IBS project. For the document
analysis form, it will be divided into 3 sections. The first section can be project
background, the second section will be types of IBS system apply by those project,
the third section will be the cost and time information for the completed IBS project.
3.4.1 Section 1: Project Background
This section contains the information of project name, project location, type
of project and gross floor area of project. Company stamp and signature also required
and compulsory for certify my research.
57
3.4.2 Section 2: Types of IBS System Apply by Project
For this section, I will identify which type of IBS system is apply by those
project. Then I also will indicate which component or element is done by IBS system.
3.4.3 Section 3: Cost and Time Information of IBS Project
This part consists of the cost and time information for those IBS project.
From the BQ that I obtain, I can abstract the breakdown element cost of project and
total time complete of project. Then I only calculate the cost per GFA and time
complete per GFA. Here is the sample of the breakdown element cost of project:
Cost Information
Table 3.4: Cost of Project For Each Elements
(RM)
Preliminaries
WBLFF
Frame
Upper Floor
Roof
Wall
Finishes
M & E
External Works
TOTAL COST OF PROJECT
58
Cost of Project/ Gross Floor Area (GFA) m2: _____________/m2
Time Information
a) Time completion of project: ____________months
b) Gross Floor Area/ month : _____________
3.5 Data Collection
Data collection is considered as a main research tools or preliminary or
supplement to the other methods when doing a research study. For this research, the
collection of data is used the quantitative method, that is case study in order to
achieve the objectives. Case study method can be described as a very useful method
that can allow the participants to analyses a real-life situation. In addition, it can give
a real and clear picture of to participant and make the research become more realistic.
3.6 Data Analysis
Data analysis means to transform a raw data into a meaningful information
that can be used or to illustrate something that can help to achieve research
objectives. Data analysis involves categorizing, scheduling and compiling evidence
acquired through data collection. For this research, the type of analysis is document
59
analysis. The document analysis has been done on the three projects for each type of
IBS system of Bill of Quantities and architecture drawings in order to get out the cost
and the gross floor area. Hence, comparison on cost and time of element project from
various type IBS will be done to find out which type IBS has the most effectiveness
on cost and time.
60
CHAPTER 4
DATA ANALYSIS
4.1 Introduction
In this chapter, researchers are focusing on the analysis on the data obtained in the
data collection stage. Due to the type of research are based on case studies, therefore, the
analysis conducted in this chapter is focused on the following projects that used the IBS
where it will be used as case studies.
This analysis is conducted based on my research objective to be achieved that is
to identify the various types of IBS systems that had been use by the contractor or
developer and to compare the cost and time among the various types of IBS systems
where this comparative study will be conducted as a whole and specifically in accordance
with the work items involved.
In the end, this research able to show the lowest cost / m2 of IBS and the fastest
speed of IBS.
61
4.2 Projects Background
The table below explained the backgrounds of nine of the same type projects
that used the IBS.
Table 4.2: Backgrounds of Nine Projects That Used the IBS.
The table above showed the backgrounds of nine projects that used the IBS.
The Project 1 is type of apartment building which is located at Kota Bharu, Kelantan
state. The owner of this project is SBJ Binajaya Development Sdn Bhd. This
PROJECT
NO.
CONTRACTOR/DEVELOPER TYPE OF
BUILDING
GFA (M2)
1 SBJ Binajaya Development
Sdn Bhd
Apartment 5,360
2 FNA Builders & Services Sdn
Bhd
Condominium 28,480
3 Ambang Rahmat Resource Apartment 8,361
4 Kim Lun Sdn Bhd Condominium 21,580
5 Setia Precast Sdn Bhd Apartment 87,062
6 Setia Precast Sdn Bhd Apartment 69,205
7 Ambang Rahmat Resources Apartment 6,255
8 IDE-Totalap Joint Venture Apartment 21,496
9 IDE-Totalap Joint Venture Condominium 7,620
62
apartment consisted 1 block of 6 floor building with 80 units. The total Gross Floor
Area for the whole apartment is 5,360 m2 or 893.33 m2 for each floor of the building.
For the Project 2, it is categorized as condominium, house where it is located
at Puchong, Selangor state. The owner of this project is FNA Builders & Services
Sdn Bhd. There are 2 blocks of 16 floors condominium consisted 220 units and 2
units of luxury pent house on top of building. The total Gross Floor Area of this
project is 28,480 m2 or 890 m2 for each floor of building.
The type of building for the Project 3 is 1 block of 5 floors of service
apartment. The project is built at Semenyih, Kajang, Selangor state. The owner of
this project is Ambang Rahmat Resource, a contractor company. This project make
of 50 units of house and the Gross Floor Area for this project is 8,361 m2.
For the Project 4, the type of building is condominium. The project is located
at JB Centre, Johor Bahru, Johor state. The owner for this project is Kim Lun Sdn
Bhd. The project make of 2block of 15 floor condominium, consists of 300 units
house and the Gross Floor Area for this project is 21,580 m2.
The type of building for the Project 5 is apartment building. The project is
located Setia Alam, Shah Alam, Selangor state. The owner for this project is Setia
Precast Sdn Bhd, also known as SP Setia Bhd Group. There are 6 block of apartment
for this project and consist 948 units houses. The Gross Floor Area for this project is
87,061 m2 or 91.84 m2 for 1 unit of apartment house.
63
The Project 6 is a block 32 storey of services apartment which has 482 units
houses. The owner of this project is Setia Precast Sdn Bhd and it located at Tebrau,
Johor Bahru, Johor. The Gross Floor Area for this project is 69,205 m2.
For the Project 7, the type of building is a block of 15 storey services
apartment which consists 150 units houses. The contractor for this project is Ambang
Rahmat Resources and the location of this project is at Setapak Jaya, Kuala Lumpur.
The Gross Floor Area for this project is 6,255m2.
The Project 8 is a block of 2 floor apartments with 2 floor of car park and 68
units of house. The contractor for this project is IDE-Totalap Joint Venture and
location of this project is at Tanjung Bungah, Pulau Pinang. The Gross Floor Area
for this project is 21,496 m2.
Last, the type of building for the Project 9 is a block of 10 floor condominium
which has 50 units of house. The project is built by the IDE-Totalap Joint Venture
and the project is located at Batu Ferringi, Pulau Pinang. The Gross Floor Area for
this project is 7,620 m2.
4.3 Types of IBS Used By The Projects
The table and figure below explained the different types of IBS that has been
used by the nine projects.
64
Table 4.3 : The Various Types Of IBS Used By The Five Projects.
Figure 4.3 : The Various Types Of IBS Used By The Five Projects.
The Table 4.4 and Figure 4.4 showed the three types of IBS used by the nie
projects which categorized under the same type of projects, apartment and
0 1 2 3 4
PRECAST CONCRETEFRAMING, PANEL AND
BOX SYSTEMS
STEEL FORMWORKS
BLOCK WORK SYSTEMS
VARIOUS TYPES OF IBS
TOTAL NO. OF IBS SYSTEMS
TYPE OF
IBS
PRECAST
CONCRETE
FRAMING, PANEL
AND BOX
SYSTEMS
STEEL
FORMWORKS
BLOCK WORK
SYSTEMS
PROJECT 1 1
PROJECT 2 1
PROJECT 3 1
PROJECT 4 1
PROJECT 5 1
PROJECT 6 1
PROJECT 7 1
PROJECT 8 1
PROJECT 9 1
TOTAL 3 3 3
65
condominium building. Project 4 , Project 5 and Project 6 are used the Precast
Concrete Framing, Panel And Box Systems. Meanwhile, Project 1 , Project 2 and
Project 9 used the Steel Formwork system. Lastly, the Project 3, Project 7 and
Project 8 is used the Block Work System.
4.3.1 Component of Building Constructed By IBS
Table 4.3.1 : Component of Building Make By IBS
The table above showed the components of building constructed by the IBS.
For the Precast Concrete Framing, Panel and Box Systems from Project 4, Project 5
and Project 6, the building components that the projects used are the precast concrete
beams and columns for the frame element, while for the slabs, its built by the solid
panels, also known as precast concrete slab. For the walls, its built by precast
concrete wall panel. For the staircase, it built by precast concrete staircase.
For the Steel Formwork from Project 1, Project 2 and Project 9, the building
components that the projects used are the concrete beams, columns, slabs, walls and
TYPE OF IBS COMPONENTS
PRECAST CONCRETE FRAMING, PANEL AND
BOX SYSTEMS Beams, columns, slabs, walls, &
staircases.
STEEL FORMWORKS Beams, columns, & walls.
BLOCK WORK SYSTEMS Beams, columns, & walls.
66
staircases which used the permanent steel formwork to cast on site. Considered as
least prefabrication IBS types but high quality finishes.
For the Block Work Systems from the Project 3, Project 7 and Project 8, the
building components that the project used are the columns, beams, slabs, walls and
staircases which used the interlocking bricks to build. The interlocking bricks are
made from manufactory and send to site construction to install.
4.4 Analysis of Cost
4.4.1 Total Cost of Projects and Cost / Gross Floor Area
The table and figure explained the total cost of nine same types of
project and its cost per GFA.
67
Table 4.4.1: The Total Cost of Projects and Cost / m2 for Nine Projects
PROJECT
NO
TYPE OF IBS TOTAL COST
(RM)
GFA
(M2)
RM/M2
PROJECT 1 STEEL FORMWORK 14,773,500 5,360 2756.25
PROJECT 2 STEEL FORMWORK 48,780,000 28,480 1712.78
PROJECT 9 STEEL FORMWORK 12,317,223 7,620 1616.43
PROJECT 3 BLOCK WORK SYSTEMS 11,646,000 8,361 1392.90
PROJECT 7 BLOCK WORK SYSTEMS 11,081,500 6,255 1771.62
PROJECT 8 BLOCK WORK SYSTEMS 18,878,951 21,496 878.25
PROEJCT 4 PRECAST CONCRETE
FRAMING, PANEL AND BOX
SYSTEM
26,017,200 21,580 1205.62
PROJECT 5 PRECAST CONCRETE
FRAMING, PANEL AND BOX
SYSTEM
81,401,000 87,062 934.98
PROJECT 6 PRECAST CONCRETE
FRAMING, PANEL AND BOX
SYSTEM
65,607,019 69,205 948.01
The Table 4.4.1 showed the total cost of projects and cost / Gross Floor Area
of nine projects for the various types of IBS which are abstract from the document
contract. There are three projects for each type of IBS. The projects that used Steel
Formwork system are Project 1, Project 2 and Project 9. For the Project 1, the total
cost of project is RM 114,773,500 and for the cost /Gross Floor Area is RM 2,756 /
m2. Next, the total cost of Project 2 is RM 48,780,000 and for the cost / Gross Floor
Area is RM 1,712 / m2. Then, for the Project 9, the total cost of project is RM
12,317,223 and the cost / Gross Floor Area is RM 1,616/m2.
Meanwhile, the projects that are used the Block Work System are Project 3,
Project 7 and Project 8. The total cost for Project 3 is RM 11,081,500 and the cost /
Gross Floor Area are RM 878 / m2. Next, the total cost for Project 7 is RM
11,081,500 and the cost / Gross Floor Area is RM 1771 /m2. Then, the total cost for
the Project 8 is RM 18,878,951 and the cost / Gross Floor Area is RM 878 /m2.
68
Project 4, Project 5 and Project 6 are used the the Precast Concrete Framing,
Panel and Box Systems. The total cost of project for Project 4 is RM 26,017,200, the
Project 5 is RM 81,401,000 and Project 6 is RM 65,607,019. The cost / Gross Floor
area for Project 4 is RM 1205 / m2, the Project 5 is RM 934 / m2 and the Project 6 is
RM 948 / m2.
4.4.2 Breakdown Cost and Cost /M2 of IBS Project Elements
Those nine projects are not total 100 percent build by IBS, there are some
elements used the IBS. By breaking down the cost of project elements, the researcher
can find out the cost / m2 of elements for the each type of project. The figure below
show the cost / m2 for each project elements.
4.4.2.1 Breakdown Cost of Element and Cost / M2 for Steel Formwork Systems
The table and figure below explained the breakdown cost and cost /m2 for
Project 1, Project 2 and Project 9 of Steel Formwork System.
Table 4.4.2.1 : Breakdown Cost of Elements and Cost / m2 for Steel Formwork
System‟s Projects.
PROJECT NO PROJECT 1 PROJECT 2 PROJECT 9
ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2
69
FRAME 3,515,000 655.78 15,300,000 537.22 2,076,090 272.45
WALL 1,200,000 223.88 2,750,000 96.56 3,015,000 395.67
TOTAL 4,715,000 879.66 18,050,000 633.78 5,091,090 668.12
The table 4.4.2.1 showed the breakdown cost of elements and cost / m2 for
Steel Formwork System‟s projects which abstract from the document contract. The
cost of each element is divided with the GFA of project in order to get the cost / m2
for each element that used the Steel Formwork System.
Figure 4.4.2.1(a): Breakdown Cost of Elements Steel Formwork System‟s Projects.
The figure 4.4.2.1(a) showed the breakdown cost of element for Steel
Formworks System‟s projects. For the Project 1 the cost of element frame is RM
3,515,000. Meanwhile, for the element walls, the cost is RM 1,200,000. The total
cost of all elements for Project 1 is RM 4,715,000. Then, for the Project 2, the cost
for the element frame is RM 15,300,000 and for the element walls, the cost is RM
2,750,000. The total cost of all elements for Project 2 is RM 18,050,000. For the
Project 9, the cost of the element frame is RM 2,076,090 and for the element walls,
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
FRAME WALL
3,515,000
1,200,000
15,300,000
2,750,000 2,076,090
3,015,000
PROJECT 1 RM
PROJECT 2 RM
PROJECT 9 RM
70
the cost is RM 3,015,000. The total cost of all elements for Project 9 is RM
5,091,093.
Figure 4.4.2.1 (b): Cost / m2 of Element for Steel Formwork System‟s Projects.
The figure 4.4.2.1 (b) showed the cost / m2 of element Steel Formwork
System‟s Projects. For Project 1, the cost / m2 for element frame is RM 655.78 / m2
and the cost / m2 for the element wall is RM 223.88 / m2. The total cost / m2 for all
elements is RM 879.66 / m2. Then, the cost / m2 of the element frame for the Project
2 is RM 537.22 / m2 and the cost /m2 of the element walls is RM 1055.48 / m2. The
total cost / m2 of element is RM 633.78/m2. For the Project 9, the cost / m2 of
element frame is RM 272.45 / m2 and the cost / m2 of the element wall is RM
395.67 / m2. The total cost / m2 for all elements is RM 668.12 / m2.
0.00
100.00
200.00
300.00
400.00
500.00
600.00
700.00
FRAME WALL
655.78
223.88
537.22
96.56
272.45
395.67 PROJECT 1 RM/M2
PROJECT 2 RM/M2
PROJECT 9 RM/M2
71
4.4.2.2 Breakdown Cost and Cost / m2 of Element for Block Work Systems
Below is the table and figure showed the cost and cost / m2 of element for
Block Work System‟s projects.
Table 4.4.2.2 : Breakdown Cost of Elements and Cost / m2 for Block Work
System‟s projects.
PROJECT NO PROJECT 3 PROJECT 7 PROJECT 8
ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2
FRAME 2,344,000 280.35 1,602,900 256.26 3,577,506 166.43
WALL 2,620,000 313.36 1,050,100 167.88 1,362,306 63.37
TOTAL 4,964,000 594 2,653,000 424 4,939,813 230
The table 4.4.2.2 showed the breakdown cost of elements and cost /m2 for
Block Work System‟s projects which abstract from document contract. The cost of
each element is divided with the GFA of project in order to get the cost / m2 for each
element that used the Block Work System.
Figure 4.4.2.2 (a): Breakdown Cost of Elements for Block Work System‟s Projects.
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
FRAME WALL
2,344,000 2,620,000
1,602,900
1,050,100
3,577,506
1,362,306
PROJECT 3 RM
PROJECT 7 RM
PROJECT 8 RM
72
The figure 4.4.2.2(a) showed the breakdown cost of element for Block Work
System‟s projects. For the Project 3, the cost of element frame is RM 2,344,000 and
for the element walls, the cost is RM 2,620,000. The total cost of element is RM
4,964,000.Then, for the Project 7, the cost of element frame is RM 1,602,900 and for
the element walls, the cost is RM 1,050,100. The total cost of element is RM
2,653,000. Lastly, for the Project 8, the cost of element frame is RM 3,577,506 and
for the element walls, the cost is RM 1,362,306. The total cost of element is RM
4,939,813.
Figure 4.4.2.2(b): Cost / m2 of Elements for Block Work System‟s Projects.
The figure 4.4.2.2 (b) showed the cost / m2 of elements for Block Work
System‟s projects. For the Project 3, the cost / m2 of the element frame is RM 280.35
/ m2 and the cost /m2 for the element walls is RM 313.36 / m2. The total cost / m2 of
element is RM 593.71/m2. Then, for the Project 7, the cost / m2 of the element frame
is RM 256.26 / m2 and for the element walls, the cost / m2 is RM 167.88 / m2. The
total cost /m2 is RM 424.14/m2. Finally, for the Project 8, the cost / m2 of the
element frame is RM 166.43 / m2 and for the element walls, the cost / m2 is RM
63.37 / m2. The total cost /m2 is RM 229.88/m2.
0.00
50.00
100.00
150.00
200.00
250.00
300.00
350.00
FRAME WALL
280.35
313.36
256.26
167.88 166.43
63.37
PROJECT 3 RM/M2
PROJECT 7 RM/M2
PROJECT 8 RM/M2
73
4.4.2.3 Breakdown Cost and Cost / m2 of Element for Precast Concrete Framing,
Panel and Box System.
The table and figure below showed the breakdown cost and cost / m2 of
element for Precast Concrete Framing, Panel and Box System‟s projects.
Table 4.4.2.3 : Breakdown Cost of Elements and Cost / m2 for Precast Concrete
Framing, Panel and Box System‟s Projects.
PROJECT NO PROJECT 4 PROJECT 5 PROJECT 6
ELEMENTS RM RM/M2 RM RM/M2 RM RM/M2
FRAME 4,676,900 216.72 9,746,000 111.94 13,309,474 192.32
UPPER FLOOR 2,250,000 104.26 4,100,000 47.09 3,652,410 52.78
WALL 2,158,000 100.00 16,079,000 184.68 1,215,413 17.56
STAIRCASE 860,000 39.85 520,000 5.97 700,325 10.12
TOTAL 9,944,900 460.84 30,445,000 349.69 18,877,622 272.78
The table 4.4.2.3 showed the breakdown cost of elements and cost / m2 for
Precast Concrete Framing, Panel and Box System‟s Projects which abstract from the
document contract. The cost of each element is divided with the GFA of project in
order to get the cost / m2 for each element that used the Precast Concrete Framing,
Panel and Box System.
74
Figure 4.4.2.3 (a): Breakdown Cost of Elements for Precast Concrete Framing,
Panel and Box System‟s Projects.
The figure 4.4.2.3 (a) showed the breakdown cost and cost/ m2 of element for
Precast Concrete Framing, Panel and Box System‟s projects. For the Project 4, the
cost of element frame is RM 4,676,900. Then, for the element upper floor, the cost is
RM 2,250,000. For the element walls, the cost is RM 2,158,000. Last, the cost of
element staircase is RM 860,000. The total cost of element is RM 9,994,900. Next,
For the Project 5, the cost of element frame is RM 9,746,000. Then, the cost of
element upper floor is RM 4,100,000 and. For the element walls, the cost is RM
16,079,000. Last, the cost / m2 for the element staircase is RM 520,000. Total cost of
element is RM 30,445,000. At last, for the element frame, the cost is RM 13,309,474.
For the element upper floor, the cost is RM 3,652,410 and. For the element walls, the
cost is RM 1,215,413. Last, the cost for the element staircase is RM 700,325. Total
cost of element is RM 18,877,622.
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
18,000,000
FRAME UPPERFLOOR
WALL STAIRCASE
4,676,900
2,250,000 2,158,000
860,000
9,746,000
4,100,000
16,079,000
520,000
13,309,474
3,652,410
1,215,413
700,325
PROJECT 4 RM
PROJECT 5 RM
PROJECT 6 RM
75
Figure 4.4.2.3(b): The Cost / m2 of Element for Precast Concrete Framing, Panel
and Box System‟s Projects.
The figure 4.4.2.3 (b) showed the cost / m2 of element for the Precast
Concrete Framing, Panel and Box System‟s Projects. For the Project 4, the cost / m2
for the element frame is RM 216.72 / m2. For the element upper floor, the cost / m2
is RM 104.26 / m2. Then, the cost / m2 for the walls is RM 100.00 / m2. Last, the
cost / m2 for the element staircase is RM 39.85 / m2. Total of the cost/m2 is RM
460.84. For the Project 5, the cost / m2 of element frame is RM 111.94 / m2. Then,
the cost / m2 for the element upper floor is RM 47.09 / m2. For the element wall, the
cost / m2 is RM 184.68 / m2. Last, the cost / m2 for the element staircase is RM 5.97
/ m2. Total cost/m2 is RM 349.69. At last, for the Project 6, the cost / m2 of element
frame is RM 192.32/ m2. Then, the cost / m2 for the element upper floor is RM
52.78/ m2. For the element wall, the cost / m2 is RM 17.56 / m2. Last, the cost / m2
for the element staircase is RM 10.12 / m2. Total cost/m2 is RM 272.78.
0.00
50.00
100.00
150.00
200.00
250.00
FRAME UPPERFLOOR
WALL STAIRCASE
216.72
104.26 100.00
39.85
111.94
47.09
184.68
5.97
192.32
52.78
17.56 10.12
PROJECT 4 RM/M2
PROJECT 5 RM/M2
PROJECT 6 RM/M2
76
4.4.3 Comparison of Cost / m2 for IBS’s Projects
Every project for each IBS system will be compared by its cost / m2. The
tables and figures below are showed the comparison of cost / m2 for each IBS for the
nine projects.
4.4.3.1 Comparison of Cost / m2 For Steel Formwork
The cost / m2 of each element for Project 1, Project 2, and Project 9 for Steel
Formwork System will be compared with each other to get which of the project get
the highest cost / m2 and the lowest cost / m2.
Table 4.4.3.1:Cost/m2 of Element for Steel Formwork‟s Projects.
PROJECT NO. TOTAL COST/M2 OF ELEMENT
PROJECT 1 RM 879.66 / M2
PROJECT 2 RM 633.78 / M2
PROJECT 9 RM 668.12 /M2
The table 4.4.3.1 showed the total cost / m2of element for Steel Formwork‟s
System‟s projects which consists the additional of total cost of Project 1, Project 2
and Project 9. The cost of element for each project can be refer to the table 4.5.2.1. .
77
Figure 4.4.3.1: Comparison of Cost / m2 of Element for Steel Formwork System.
The figure 4.4.3.1 showed the comparison cost / m2 of three projects for Steel
Formwork. The cost / m2 for the Project 1 is RM879.86 / m2, which is the highest of
cost / m2. Then, the cost / m2 for the Project 2 is RM633.78 / m2, which is the
lowest cost / m2. Last, the cost / m2 for Project 9 is RM668.12 / m2.
The reason that the Project 1 become the highest cost / m2 because this
project used the Circular Steel Formwork to build the circular columns which is
expensive compare to the other two projects used the normal type of steel formwork,
that is Flat Form Panel for build the square columns, beams, floor slab and others.
0.00 200.00 400.00 600.00 800.001000.00
TOTAL COST/M2
879.66
633.78
668.12
PROJECT 9 RM / M2
PROJECT 2 RM /M2
PROJECT 1 RM / M2
78
4.4.3.2 Comparison of Cost / m2 For Block Work System
The cost / m2 of each element for Project3, Project 7, and Project 8 for Block
Work System will be compared with each other to get which of the project get the
highest cost / m2 and the lowest cost / m2.
Table 4.4.3.2 : Total Cost/m2 of Element for Block Work System‟s Projects.
PROJECT NO. TOTAL COST/M2 OF ELEMENT
PROJECT 3 RM 593.71 / M2
PROJECT 7 RM 424.14 / M2
PROJECT 8 RM 229.80 /M2
The table 4.4.3.1 showed the total cost / m2of element for Block Work
System‟s projects which consists the additional of total cost of Project 3, Project 7
and Project 8. The cost of element for each project can be refer to the table 4.5.2.2. .
79
Figure 4.4.3.2: Comparison of Cost / m2 of Element for Block Work System.
The figure 4.4.3.2 showed the comparison cost / m2 of three projects for Steel
Formwork. The cost / m2 for the Project 3 is RM593.71 / m2, which is the highest of
cost / m2. Then, the cost / m2 for the Project 7 is RM424.14 / m2.Last, the cost / m2
for Project 8 is RM229.80 / m2, which is the lowest cost / m2.
The Project 3 get the highest cost /m2 and the Project 8 get the lower cost /
m2 because of the material for walls which Project 3 used Interlocking Brick System
and Project 8 used the Lightweight Masonry Block to build the walls.
0.00 200.00 400.00 600.00
TOTAL COST/M2
593.71
424.14
229.80 PROJECT 8 RM / M2
PROJECT 7 RM / M2
PROJECT 3 RM / M2
80
4.4.3.3 Comparison of Cost / m2 For Precast Concrete Framing, Panel and Box
System
The cost / m2 of each element for Project 4, Project 5, and Project 6 for
Precast Concrete Framing, Panel and Box System will be compared with each other
to get which of the project get the highest cost / m2 and the lowest cost / m2.
Table 4.4.3.3 : Total Cost/m2 of Element for Precast Concrete Framing, Panel and
Box System‟s Projects.
PROJECT NO. TOTAL COST/M2 OF ELEMENT
PROJECT 4 RM 593.71 / M2
PROJECT 5 RM 424.14 / M2
PROJECT 6 RM 229.80 /M2
Figure 4.4.3.3: Comparison of Cost / m2 of Element for Precast Concrete Framing,
Panel and Box System.
0.00 100.00 200.00 300.00 400.00 500.00
TOTAL COST/M2
460.84
349.69
272.78
PROJECT 6 RM / M2
PROJECT 5 RM / M2
PROJECT 4 RM / M2
81
The figure 4.4.3.3 showed the comparison cost / m2 of three projects for
Precast Concrete Framing, Panel and Box System. The cost / m2 for the Project4 is
RM460.84 / m2, which is the highest of cost / m2. Then, the cost / m2 for the Project
5 is RM349.69 / m2.Last, the cost / m2 for Project 6 is RM272.78 / m2, which is the
lowest cost / m2.
The Project 4 has the highest cost / m2 and the Project 6 has the lowest cost /
m2 because of the different type of precast concrete slab. The Project 4 is used the
Precast Concrete Hollow Core Slab which is a unique design of floor slab that can
allow wire go under the slab. The Project 6 is used the Precast Concrete Wide Slab, a
simple design of floor slab for minimum the cost and time.
4.4.4 Overall Comparison Average Cost / m2 for IBS Project
TYPE OF IBS
TOTAL
COST/M2
(RM)
TOTAL
NO.
PROJECT
AVERAGE
COST/M2
(RM)
Precast Concrete Framing ,
Panel and Box System 1083.31 3 361.10
Steel Formwork System 2181.56 3 727.19
Block Work System 1247.65 3 415.88
Table 4.4.4 : Overall Average Cost/m2 for All IBS Project.
The table 4.5.4 showed the overall average cost/m2 for all IBS project. The
total cost/m2 of each type IBS system is divided with the total number of project to
get the average cost/m2 for each IBS system. Then, the average cost/m2 of each IBS
system will be compared to get which type of IBS has the lowest and the highest of
cost/m2.
82
Figure 4.4.4: Overall Average Cost/m2 for All IBS Project.
The table 4.4.4 and figure 4.4.4 showed the overall average cost / m2 for all
type IBS project. For the projects of Precast Concrete Framing, Panel and Box
System, the average cost / m2 is RM361.10 / m2, which is the lowest average cost /
m2 among three type of IBS. Then, the average cost / m2 for Steel Formwork System
is RM727.19 / m2, the highest average cost / m2 among three types of IBS. Last, the
average cost / m2 for Block Work System is RM 415.88 / m2.
Most of the components and the elements of projects of this IBS system are
built by Precast Concrete Framing, Panel and Box System and the components is
fully make at factory before send to the site for the installation .The costs is lower
compare to other IBS system, the Steel Formwork System and Block Work System
because it do not need skilled worker to install this component on the site as the cost
of skill worker is expensive than the non-skilled worker.
0.00
200.00
400.00
600.00
800.00
PrecastConcreteFraming ,Panel and
Box System
SteelFormwork
System
Block WorkSystem
361.10
727.19
415.88
Overall Average Cost/m2 for All IBS Project
AVERAGE COST/M2 (RM)
83
4.5 Analysis of Time
It is very important to know the time completion of project. The purpose is
to know the speed of construction based on its gross floor area over the time of
completion for the nine of same types of project.
4.5.1 Total Time Completion and Comparison of GFA / Time of Project
Table 4.5.1:Total Time Completion and the GFA / time of Project.
PROJECT NO TIME COMPLETION (MONTHS) M2 / MONTH
PROJECT 1 15 357.33
PROJECT 2 26 1095.38
PROJECT 3 12 696.75
PROJECT 4 24 899.17
PROJECT 5 26 3348.54
PROJECT 6 24 2883.54
PROJECT 7 19 329.21
PROJECT 8 24 895.67
PROJECT 9 18 423.33
The table 4.5.1 showed the total time completion and the GFA / time of
project which abstract from the document contract. Then, the GFA/time of project
for each project for every IBS systems will be compared to find the fastest and the
slowest speed of IBS system.
84
4.5.1.1 Total Time Completion and Comparison of GFA/ time of Project for
Steel Formwork System
Table 4.5.1.1:Total Time Completion and GFA/time of Project for Steel Formwork
System.
PROJECT NO. TIME COMPLETION
(MONTH)
GFA (M2) M2 / MONTH
PROJECT 1 15 5,360 357.33
PROJECT 2 26 28,480 1095.38
PROJECT 9 18 7,620 423.33
The table 4.5.1.1 showed the total time completion and GFA/time of project
for Steel Formwork System. The total time completion of Project 1, Project 2 and
Project 9 will be divided with each GFA in order to get the GFA/month.
Figure 4.5.1.1(a): Total Time Completion for Steel Formwork System‟s Projects.
0
5
10
15
20
25
30
PROJECT 1 PROJECT 2 PROJECT 9
15
26
18
TIME COMPLETION(MONTHS)
85
The figure 4.5.1.1(a) showed the total time completion and GFA/ month of
project for Steel Formwork System. The total time completion for Project 1 is 15
months. Then, the total time for Project 2 is 26 months. Finally, the total time
completion for Project 9 is 18 months.
Figure 4.5.1.1(b): Comparison of GFA / time for Steel Formwork System‟s Projects.
The figure 4.5.1.1(b) showed the comparison of GFA / time for Steel
Formwork System‟s projects. For the Project1, the GFA / month is 357.33 m2 /
month, which is the lowest GFA / month. Then, the GFA / month for the Project 2 is
1095.38 m2 / month, which is the highest GFA / month. Finally, the GFA / month for
the Project 9 is 423.33 m2 / month.
0.00
200.00
400.00
600.00
800.00
1000.00
1200.00
PROJECT 1 PROJECT 2 PROJECT 9
357.33
1095.38
423.33 M2 / MONTH
86
4.5.1.2 Total Time Completion and Comparison GFA/ time of Project for Block
Works System
Table 4.5.1.2:Total Time Completion and GFA / time of Project for Block Works
System.
PROJECT NO. TIME COMPLETION
(MONTH)
GFA (M2) M2 / MONTH
PROJECT 3 12 8,361 696.75
PROJECT 7 19 6,255 329.21
PROJECT 8 24 21,496 895.67
The table 4.5.1.2 showed the total time completion and GFA/time of project
for Block Works System. The total time completion of Project 3, Project 7 and
Project 8 will be divided with each GFA in order to get the GFA/month.
Figure 4.5.1.2(a): Total Time Completion Project for Block Work System.
0
5
10
15
20
25
PROJECT 3 PROJECT 7 PROJECT 8
12
19
24
TIME COMPLETION(MONTHS)
87
The figure 4.5.1.2 (a) showed the total time completion and GFA/ month of
project for Block Work System. The total time completion for Project 3 is 12 months.
Then, the total time for Project 7 is 19 months. Finally, the total time completion for
Project 8 is 24 months.
Figure 4.5.1.2(b): Comparison GFA / time of Project for Block Work Systems.
The figure 4.5.1.2(b) showed the comparison GFA/time of project for Block
Work Systems. For the Project 3, the GFA / month is 696.75 m2 / month. Then, the
GFA / month for the Project 7 is 329.21 m2 / month, which is the lowest GFA /
month. Finally, the GFA / month for the Project 8 is 895.67 m2 / month, which is the
highest GFA / month.
0
100
200
300
400
500
600
700
800
900
PROJECT 3 PROJECT 7 PROJECT 8
696.75
329.21
895.67
M2 / MONTH
88
4.5.1.3 Total Time Completion and Comparison GFA/ time of Project for
Precast Concrete Frame, Panel and Box System
Table 4.5.1.3:Total Time Completion and GFA / time of Project for Precast Concrete
Frame, Panel and Box System.
PROJECT NO. TIME COMPLETION
(MONTH)
GFA (M2) M2 / MONTH
PROJECT 4 24 21,580 696.75
PROJECT 5 26 87,062 329.21
PROJECT 6 24 69,205 895.67
The table 4.5.1.3 showed the total time completion and GFA/time of project
for Precast Concrete Frame, Panel and Box System. The total time completion of
Project 4, Project 5 and Project 6 will be divided with each GFA in order to get the
GFA/month .
Figure 4.5.1.3(a): Total Time Completion of Project for Precast Concrete Frame,
Panel and Box System.
23
23.5
24
24.5
25
25.5
26
PROJECT 4 PROJECT 5 PROJECT 6
24
26
24
TIME COMPLETION(MONTHS)
89
The figure 4.5.1.3(a) showed the total time completion and GFA/ month of
project for Precast Concrete Frame, Panel and Box System. The total time
completion for Project 4 is 24 months .The total time completion for Project 5 is 26
months and finally, the total time completion for Project 6 is 24 months.
Figure 4.5.1.3(b): Comparison GFA/time of Project for Precast Concrete Frame,
Panel and Box System.
The figure 4.5.1.3(b) showed the comparison GFA/time of project for Precast
Concrete Frame, Panel and Box System. For the Project 4, the GFA / month is
899.17m2 / month, which is the lowest GFA / month. While, for the Project 5, the
GFA / month is 3,348.54 m2 / month, which is the highest GFA / month. Last, the
GFA / month for the Project 6 is 2,883.54 m2 / month.
0.00
500.00
1000.00
1500.00
2000.00
2500.00
3000.00
3500.00
PROJECT 4 PROJECT 5 PROJECT 6
899.17
3348.54
2883.54
M2 / MONTH
90
4.5.2 Overall Comparison of Average GFA / Month for IBS
The table and figure below showed the average GFA / Month for all type IBS
project.
Table 4.5.2: Average GFA / Month for All Type IBS Projects.
TYPE OF IBS
GFA /
MONTH
TOTAL
PROJECTS
AVERAGE GFA
/ MONTH
STEEL FORMWORK
SYSTEM 401.33 3 133.78
BLOCK WROK SYSTEM 1921.63 3 640.54
PRECAST CONCRETE
FRAME, PANEL AND BOX
SYSTEM 7131.25 3 2377.08
The table 4.5.2 showed the average GFA / month for all type IBS projects
which will be compared with each other to get the speed of construction. To get the
average GFA/month, the total of GFA/month for each type IBS system will be
divided with the total projects. The highest of average GFA/month of IBS is the
fastest speed of construction.
91
Figure 4.5.2: Average GFA / Month for All Type IBS Project.
The table 4.6.2 and figure 4.6.2 showed the average of GFA / Month for all
type IBS projects. The Precast Concrete Frame, Panel and Box System has the
highest average GFA / month, 2377.08 m2 / month, mean that the project that used
this IBS has the fastest speed of construction. Then, the average GFA / month for
Block Work System is 640.54 m2 / month. Last, the average GFA / month for Steel
Formwork is 133.78 m2 / month, which is the lowest average GFA / month. It mean
that the projects used this IBS system has the slowest speed of construction.
The Precast Concrete Frame, Panel and Box System has the highest average
GFA/month or highest speed of construction because the components and elements
are made at factory and direct install on the site without using the skilled workers
compare to other type of IBS systems which using the skilled workers to used it.
0.00 1000.00 2000.00 3000.00
STEEL FORMWORK SYSTEM
BLOCK WROK SYSTEM
PRECAST CONCRETE FRAME,PANEL AND BOX SYSTEM
133.78
640.54
2377.08
Average GFA / Month for All Type IBS
AVERAGE GFA / MONTH
92
4.6 Conclusion
Based on the research analysis that has been done on cost and time overall
projects for the various types of IBS, a very satisfied result has come out. For the
cost, the result showed that the Steel Formwork System has the highest average cost /
m2 that is RM727.19 / m2 and Precast Concrete Framing, Panel and Box System has
the lowest average cost / m2 that is RM361.10 / m2. For the m2 / time of project
completion, the Precast Concrete Framing, Panel and Box System has the fastest
speed of completion project, that is 2,377.08 / month of the average GFA / month
and Steel Formwork System has the slowest speed of completion project, that is
133.78 m2 / month of the average GFA / month. It can be concluded Precast
Concrete Framing, Panel and Box System as the most effectiveness IBS among this
three types of IBS.
97
CHAPTER 5
CONCLUSION AND RECOMMENDATION
5.1 Introduction
Summary of the study will be discussed in this chapter 5 where conclusions
are made based on the results of the analysis in chapter 4. The conclusions made are
covering the entire research that has been conducted on nine of same types of
residential projects that used the IBS has been selected. In this chapter also will
discuss the problems facing during conducting the research. Next, the proposed for
the future research will be suggested in this chapter.
5.2 Summary
In this research, two objectives have been decided so the evaluation towards
the hypothesis can be made. The first objective is to identify the various types of IBS
systems that have been used in Malaysian construction industry. The second
98
objective is to identify the different of cost and time on various types of IBS systems.
The comparison was made and identified based on the cost / gross floor area and
gross floor area / time completion project for every types of project.
For this research, total nine IBS project had been selected. Each IBS have the
three same type of project. There are three projects used Precast Concrete Framing,
Panel and Box System, the Steel Formwork, and the Block Work System.
In order to get the best result of the research, comparison has done on every
three projects of each IBS system to get the average cost / m2 and the GFA / month.
The result of analysis showed the Precast Concrete Framing, Panel and Box System
has the lowest average cost / m2, that is RM361.10 / m2, the Steel Formwork System
has the highest average cost / m2, that is RM727.19 / m2 and the average cost / m2
of Block Work System is RM415.88 / m2. For the time, the Precast Concrete
Framing, Panel and Box System has the highest average GFA / month, that is
2377.08 m2 / month. Then for the Steel Formwork, it has the lowest GFA / month,
that is 133.78 m2 / month. The average GFA / month for Block Work System is
640.54 m2 / month.
At the end of research, the Precast Concrete Framing, Panel and Box System
is the most effective IBS system overall type of IBS system by having the lowest
average cost / m2 and average GFA / month. The result can be proven by looking at
the analysis cost / m2 and m2 / time completion of project.
So, I do really hope in the next future the IBS systems can be practice widely
in our construction industry in addition to aid and fix the weakness of conventional
method of construction.
99
5.3 Problems Facing During The Research
During conducting the research, there are few problems occurs and
complicate the research process. The problems that occurs are :
a) Faced difficulty to find source and data for writing the literature to be
match with the issues.
b) Difficulty to get the documents like BQ and drawing because those
documents are private and confidential.
c) Facing problems when meeting the contractor and developer whose are not
willing to give the cost and time data of project.
5.4 Suggestions and Recommendations
After the research has been done, there are few suggestions of proposal to be
suggested for the future research proposed. The following suggestions are :
1) Analysis The Constructability On Various Type of IBS Systems.
2) Analysis The Risk Management of IBS Systems On Site Construction.
100
3) Compare the Effectiveness Cost, Time and Constructability of IBS
Systems and Green Building Systems.
101
REFERENCE
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APPENDIX A
DEPARTMENT OF QUANTITY SURVEYING
FACULTY OF BUILT ENVIRONMENT
CASE STUDY TITLE:
THE EFFECTIVENESS COST AND TIME ON
VARIOUS TYPES OF IBS SYSTEM.
Objectives:
To identify the various types of IBS system.
To evaluate the cost and time among the various types of IBS system.
This is used to collect data for the study above. All information disclosed will be
treated strictly CONFIDENTIAL and will only be used for academic purposes.
Thank you.
Prepared by:
Goh Tuan Leong (B11BE0010)
900215-03-5213
3SBEQ (Bachelor of Quantity Surveying)
Email: [email protected]
Tel: 013-3114308
Supervisor: Associate Professor Sr Dr Zakaria Mohd Yusof
Company‟s Stamp
Section A
1) Project Background
a) Name of Project: ______________________________________________
b) Project Location : ___________________________________________
c) Type of Project :
Residential Commercial School Factory
Others:___________
d) Gross Floor Area of Project (GFA) :__________________m2
Section B
1) Type of IBS Systems
a) Which type of IBS do the project used?
Precast Concrete Framing, Panel and Box Systems
Steel Formwork Systems
Steel Framing Systems
Timber Framing Systems
Block work Systems
Others __________________
b) Which part/component of building is done by IBS system?
Slabs
Beams
Columns
Walls
Others :____________
Section C
1) Cost Information
a) Breakdown Cost of Project
(RM)
Preliminaries
WBLFF
Frame
Upper Floor
Roof
Wall
Finishes
M & E
External Works
TOTAL COST OF PROJECT
b) Cost of Project/ Gross Floor Area (GFA) m2: _____________/m2