ibs wilayah sabah

IBSDIGEST
Penerbitan Majalah Promosi / Sistem Binaan Berindustri (IBS) • Julai – September 2005 • ISBN 983-2724-29-5
Prefabricated
Steel Buildings
Provide an Economical
Construction Alternative
Precast
Installation
PROCEDURES
REALISING THE INDUSTRIALISATION
OF MALAYSIAN CONSTRUCTION INDUSTRY:
IBS
A SHORT
HISTORY
Soalan-soalan
Yang Seringkali Ditanya (FAQs)
Mengenai Sistem
Binaan Berindustri (IBS) dan
Kordinasi Modular (MC)
Program Promosi
CONSTRUCTION IBS WILAYAH
IT PERSPECTIVE SABAH
IBSDIGEST
A quarterly promotional publication on Industrialised Building Systems • July – September 2005 • ISBN 983-2724-29-5
KANDUNGAN
Dari Meja Pengarang
1
Prefabricated Steel Buildings
Provide an Economical Construction Alternative
2
Precast Installation Procedures
3
Realising The Industrialisation
Of Malaysian Construction Industry:
Construction IT Perspective
6
IBS A Short History
7
Soalan-soalan
Yang Seringkali Ditanya (FAQs) Mengenai Sistem
Binaan Berindustri (IBS) dan Kordinasi Modular (MC)
9
Program Promosi IBS Wilayah Sabah
11
Promosi IBS Wilayah Sarawak
12
Kompleks Sukan Nasional adalah binaan yang paling
menyerlah di Kompleks Sukan Nasional Bukit Jalil. Laluan
masuknya diperindahkan dengan arca keris sebagai
lambang keperkasaan. Didirikan sebagai stadium untuk
pelbagai acara, Kompleks Sukan ini menjadi lokasi untuk
penganjuran pelbagai acara atletik, perlawanan bola
sepak, pembukaan rasmi serta pelbagai acara bersejarah.
Kompleks ini yang terletak 20km dari bandaraya Kuala
Lumpur ini telah berjaya disiapkan oleh United Engineers
tiga bulan lebih awal dari jadual.
Kompleks Sukan Nasional Bukit Jalil berjaya disiapkan
pada tahun 1998 untuk Sukan Komanwel Kuala Lumpur.
Struktur yang paling menyerlah di Kompleks Sukan ini,
Stadium Nasional; adalah salah sebuah gelanggang
sukan pelbagai acara yang terbesar dan paling moden di
dunia. Kebanyakan komponen stadium dengan kapasiti
80,000 tempat duduk ini telah dibina menggunakan
kaedah pembinaan IBS. Ini termasuk struktur bumbung
keluli. breaches konkrit pratuang dan fasad berseni bina
serta rangka keluli yang merupakan struktur utamanya.
Beberapa struktur IBS lain yang terletak berhampiran
kompleks ini termasuk Perkampungan Sukan Komanwel,
Komanwel Vista, stadium tertutup dan stadium hoki
menggunakan pembinaan hybrid in-situ dan pratuang
Penasihat
Datuk Ir. Hamzah Hasan
Megat Kamil Azmi Megat Rus Kamarani
Kami mengalu-alukan komen, artikel dan
sebarang bentuk pengiklanan daripada
pembaca. Sila hubungi:
Kumpulan Pengarang:
Ir. Elias Ismail
Ir. Shahrul Nizar Shaari
Rofizlan Ahmad
Rozaiman Hassan
Syurhawati Abdul Rahim
Unit Pembangunan Teknologi,
Bahagian Pembangunan Teknologi
CIDB Malaysia
Tgkt. 8, Grand Seasons Avenue
No. 72, Jalan Pahang, 53000 Kuala Lumpur
Tel: 603-26170200
Faks: 603-40451808
e-mel: [email protected], [email protected]
Laman Web: www.cidb.gov.my
ISSUE • JULY – SEPTEMBER 2005
Dari
Meja Pengarang
Banyak faktor menyumbang kepada kelembapan prestasi industri
pembinaan masakini. Salah satu daripadanya ialah kekurangan
tahap daya saing yang cukup teguh untuk bersaing di pasaran yang
semakin hebat persaingannya. Penggunaan teknologi pembinaan;
misalnya melalui penggunaan Sistem Pembinaan Berindustri
(IBS), seseorang kontraktor boleh mendahului pesaingnya di
pasaran dalam negara. Penggunaan IBS membolehkan kualiti,
produktiviti, keberkesanan dari segi kos, keselamatan, ketepatan
tarikh penyiapan dan kepuasan pelanggan mencapai tahap yang
jauh lebih tinggi berbanding pembinaan secara konvensional.
Walaupun pasaran dalam negara menyediakan peluang kerja yang terhad
sekalipun, namun dengan daya saing
yang tinggi melalui penggunaan IBS,
perkhidmatan pembinaan negara masih
boleh dipasarkan ke pasaran antarabangsa yang banyak menyediakan peluang perniagaan pembinaan.
Isu IBS Digest keluaran ini memberi
tumpuan kepada Pre-Engineered Buildings (PEB), yang seringkali dirujuk sebagai proses binaan pre-fabrikasi atau binaan keluli pre-fab iaitu kaedah pembinaan yang digunakan secara meluas di
Amerika Syarikat serta beberapa buah
negara maju yang lain. Ia merangkumi
satu sistem binaan berangka keluli dengan komponen yang telah direkabentuk
terlebih dahulu yang mudah dimuatkan
ke dalam pelbagai kombinasi yang luas
untuk memenuhi keperluan penggunaan akhir khusus yang unik. PEB amat
sesuai digunakan bagi pemasangan
tetap.
Antara kelebihan PEB berbanding pembinaan keluli konvensional
termasuk: penjimatan kos hasil kerja
kejuruteraan yang dijalankan di kilang
– PEB boleh mencapai sehingga 40%
penjimatan kos berbanding pembinaan
secara konvensional; memerlukan asas
yang lebih mudah; lekapan (seperti pintu dan tingkap) mengikut standard yang
mudah dan cepat ditukar; pengurangan
tempoh siap pembinaan – lazimnya
bangunan boleh dibina hanya dalam
tempoh beberapa minggu sahaja;
proses pemasangannya boleh dilakukan
dengan cepat dan cekap – boleh menjimatkan kos sehingga 20% berbanding
penggunaan keluli konvensional; rekabentuk secara modular – struktur PEB
boleh diubah dan diperbesarkan dengan
cepat dan mudah apabila diperlukan.
Oleh kerana IBS merupakan kaedah
pembinaan yang menjanjikan penyiapan yang lebih cepat, menjimatkan
kos, menjamin kualiti binaan, tahap
keselamatan yang lebih tinggi, tidak
memerlukan tenaga kerja yang ramai
dan pelbagai manfaat lain; dalam jangkamasa panjang, walaupun kos untuk
menggunakan kaedah ini mungkin memerlukan pelaburan permulaan yang
agak tinggi sedikit, tetapi kos pelaburan
tambahan ini mampu memberi pulangan yang menguntungkan. Oleh itu,
beralihlah daripada kaedah pembinaan
konvensional kepada kaedah Pembinaan Secara Berindustri.
IBSDIGEST 1
Features
ISSUE • JULY – SEPTEMBER 2005
Prefabricated Steel Buildings
Provide an Economical Construction Alternative
The term “steel building” is often associated with simple storage sheds and basic structures. With
advancements in the industry over the past forty years, however, steel buildings have broken that
stereotype and are being used for an ever-growing list of larger and more complex applications.
Steel has found its way into advanced farm buildings, riding arenas, aircraft hangars, commercial
centers and more.
Prefabricated Steel Building
Background
The 20th century marked the beginning
of the steel building industry. With the
widespread use of automobiles in the
early 1900s, one of the first uses of steel
building was the garage. As consumers saw the low cost and value of steel,
storage facilities, garages and storage
sheds made of galvanized steel quickly
spread around the country. In the first
decade of the 1900s innovative builders also created farm storage buildings
and grain bins out of steel instead of
wood. By the end of the Depression,
these storage bins had proven their durability when compared to wood structures. This was validated in 1938, when
the U.S. Department of Agriculture ordered 30,666 steel grain bins to store
surplus crops. This order amounted to 1
½ times the number of steel grain bins
created by the entire industry only one
year before.
In 1940 Butler Manufacturing Company introduced the first line of prefabricated steel buildings using rigid frame
design. (A rigid frame is a skeleton for
the building’s framework, made of
steel girders.) This allowed businesses
to purchase larger and more capable
steel buildings at a lower cost and with
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IBSDIGEST
a shorter construction schedule. By this
time, the aeronautical world had embraced steel as well; steel aircraft hangars were being widely used in the civilian and military sectors.
Following World War II, engineers
continued to improve prefabricated
steel buildings, increasing the size and
sophistication of these building “kits.”
The Metal Building Manufacturers Association (MBMA) was founded in 1956
to drive innovation, standardization,
and greater acceptance of prefabricated steel buildings. Their efforts have
worked; the MBMA estimates that steel
building systems were used for about $1
million of new construction in 1960. In
2000, steel building systems accounted
for almost 1.16 billion square feet and
$2.5 billion of new low-rise commercial
construction.
Steel Building Advantages
One reason for the fast growth of the
prefabricated steel building industry is
the fact that steel building manufacturers have created prefabricated systems
for a wide range of applications. Steel
buildings used to be limited to storage
facilities and aircraft hangars. Now, steel
is used very successfully for structures as
small as toll booths and vending machine shelters, and as large as barns and
agricultural facilities, workshops, sports
facilities, even churches and retail centers. Steel buildings are frequently used
in larger buildings like commercial aircraft hangars and sports arenas, where
a large clearspan space is required. (Clearspan is an interior space of a building
where the roof is supported by the bordering structural walls and framework,
and not with columns.)
Steel provides some other benefits in many circumstances. Generally
speaking, prefabricated steel buildings
can also be erected more quickly than
traditionally constructed buildings. Assuming that the prefabricated kit does
not require significant customizing,
the project’s design phase is reduced
considerably with the use of the steel
building system. While this is true for
the design phase, site preparation and
construction phases for larger steel
buildings are normally comparable with
similarly sized tilt-up structures.
Perhaps the main reason for the
expanding the use of steel buildings
is construction cost. Assuming that
the building fits the parameters and
limitations of what is appropriate for
steel, prefabricated steel building kits
are generally less expensive than custom-designed structures built using
traditional construction or even tilt-up
construction. Also, with the use of finishes, facades and other wall claddings,
builders can craft beautiful facilities
that avoid the traditional “tin shed”
look associated with steel buildings.
For smaller warehouse, industrial
and commercial projects, particularly
those fewer than 50,000 square feet,
these benefits make steel buildings an
extremely attractive alternative for the
cost-conscious building owner. Also,
steel buildings are frequently the right
choice for larger buildings where a
large clearspan space is required.
By Rozaiman Hassan
Manager Construction Technology
Development Division
Features
JOKE
ISSUE • JULY – SEPTEMBER 2005
Precast Installation
PROCEDURES
An engineer, doctor, and lawyer
golfing. A pastor, a doctor and an
engineer were waiting one morning for a particularly slow group of
golfers.
Engineer: What’s with these guys?
We must have been waiting for 15
minutes!
Doctor: I don’t know, but I’ve
never seen such ineptitude!
Lawyer: Hey, here comes the
he can do for them.
Precasters who do their own installation
know there are procedures required to
achieve a high level of quality, customer
satisfaction and, most important, safety.
Since every installation is unique, procedures may vary and can become complex.
Every company develops its own
special way of installing precast. The
methods, tools, and supplies used are
usually tailored after performing many
installations. Networking with other
precasters is often the best way to determine efficient procedures.
To make installations run smoothly,
it is best to have experienced workers.
Plants should take the initiative and
train employees, developing them into
highly skilled installers. This goes for
foremen, welders, crane operators, and
the whole crew. If procedures are kept
simple and consistent, installation workers can achieve efficient, safe, and costeffective installations while improving
their track records each time.
Engineer: Why can’t these
Planning
greens keeper. Let’s have a word
with him. [dramatic pause] Hi
George. Say, what’s with that
group ahead of us? They’re rather
slow, aren’t they?
George: Oh, yes, that’s a group of
blind fire fighters. They lost their
sight saving our clubhouse from a
fire last year, so we always let them
play for free anytime.
The group was silent for a moment.
Lawyer: That’s so sad. I think I
will say a special prayer for them
tonight.
Doctor: Good idea. And I’m going to contact my ophthalmologist
buddy and see if there’s anything
guys play at night?
Installation is all about planning. You
need to determine the best routes
and time to the site, access to the site,
ground conditions and size of the site
before installation works can be done.
Site limitations can lead to difficult and
time-consuming installations that may
require special lifting hardware and additional machinery. These will add costs
to installation in your quote.
It is a good idea to make detailed
checklists of all the supplies that will be
needed at the job site. Big, complex jobs
or jobs located at a fair distance from
plants will require a more extensive list
than smaller or closer distance jobs. It is
always better to come prepared than to
send someone to scout for supplies and
materials during the installation.
The most important aspect of an
installation is the safety of your workers and anyone on or near the jobsite.
Installer must have a detailed safety procedure in their method of statement for
installation that meets all Department of
Occupational Safety and Health (DOSH).
Other than that, Crane operators also
must be certified to meet DOSH requirements.
The hazards associated with a precast installation procedure can be very
different from other type of works
at site. The main thing for workers to
keep in mind is to be constantly aware
of their surroundings. Workers should
practise clear and concise communication, know the rules and regulations,
and watch out for others.
IBSDIGEST 3
Features
The following are just a few safety procedures to follow for installation:
• Workers should at no time be
underneath a suspended product.
• When aligning products, use
objects like 2x4s, bars, shims,
wedges, or other tools to stop the
precast from hitting other objects.
Do not use your hands or feet!
• When working at heights, make
sure all safety equipment is used
properly at all times, no matter how
long the task may take.
• Use ladders according to
manufacturers' recommendations
and secure when appropriate.
• If work is to be done in excavations,
make sure that the shoring is
adequate.
Successful Installation
Requires Teamwork
Once a contract has been awarded, a
meeting should be held with those involved with the job construction prior to
installation. The meeting should cover
aspects such as site access, product
size and weight limitations, installation
scheduling, storage issues, and liability
issues. It is crucial that owners and other
parties of the construction phase understand the precast installation procedure and also how the finished product
should function and look. This makes
the process easier for everyone and
many times ensures timely payment.
Delivery trucks must have clear access to the site and be able to maneuver
around the site safely, without causing any product damage. The site area
must accommodate product handling
and possibly storage. For lengthy jobs,
products may need to be stored in areas where they are protected and where
they do not interfere with other work
on site.
A critical hazard to document is
overhead wires. The site must have sufficient room for a boom or crane to move
product around without coming in close
proximity or in contact with any wires.
If any underground utilities exist, their
location must be known and marked. A
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IBSDIGEST
ISSUE • JULY – SEPTEMBER 2005
well-drained, stable site is necessary in
order to support trucks, cranes and their
outriggers.
Scheduling
Scheduling the installation can range
from simple to complex for jobs and involve many construction phases. Schedules should be reviewed and agreed
upon by the general contractor and/or
the construction manager.
The precast schedule should include
detailed installation sequencing information. The procedure should allow for as
few crane moves as possible. Before the
precast product leaves the plant yard,
determine the order in which pieces are
needed on site. At the site, pieces can
be easily installed in the predetermined
order if they have been shipped in the
correct order. An experienced installer
will prove helpful in these situations,
especially if it is necessary to alter the
order. Prior to delivering precast product and having expensive cranes, other
equipment, and installation crews show
up at the site, it is essential that the site
be properly prepared. The more site
preparation you do, the smoother, and
it is hoped, less costly the installation
will go.
Lifting systems
Most precast units can be installed using standard two- and four- point picks.
If products do not need to be flipped
or turned vertically, they can be lifted
straight off of truck beds and into their
final location. Very large and heavy or
odd-shaped units may require more
complex lifting systems. If units must be
flipped vertically and rotated, more specialized lifting apparatus will need to be
hooked up to the crane.
Most lifting apparatuses consist of
wire ropes or chains employing spreader bars, hooks, shackles, rolling blocks,
closed links, and lifting plates to complete the assembly. All hardware should
have annual certification to verify capacity and safe working loads generally is
required. DOSH have strict regulations
on lifting systems.
Connections or threaded anchor
holes should be free of debris. Make
sure inserts are also clean and greased if
necessary. Check for burrs on threaded
inserts. Do not over tighten bolts, especially ones close to product edges,
and protect the precast product from
chipping when aligning. Wood, rubber,
wedges, and plastic shims work well for
this.
Sometimes, location elevations, pins,
holes, or attachments may be incorrect.
To attach products using bolts or plates,
expansion bolts may be inserted into
the precast in alignment with structural
connections. In this case, make sure
holes are drilled at structurally sound
locations. It is sometimes inevitable that
steel will be encountered upon drilling.
Or, new plates may be welded either to
the precast or on the fixed structure.
Chemical anchors (resin capsule or epoxy anchors) can be used in place of
expansion anchors for use with heavy
loads. However, excessively high heat
can degrade these chemical anchors.
Be aware of manufacturers load ratings
and recommendations. If structural connections require field modification, an
engineer should be consulted.
If foundation elevations or existing
product dimensions are wrong, either
they will have to be fixed or the precast
may need to be cut to fit. Incorrect base
elevations that prohibit pipe or other
utility connections will also likely require
modification or new holes will have to
be cut in the precast.
Installing products such as lintels
and windowsills can be a complex process because of the nature of their final locations. Often, the surrounding
pieces are already in place. Cases where
product must fit vertically in between
existing structures can also be complex.
Since the product is usually lifted from
points either on top or on the back of
the product, the lifting devices will likely
have to be disconnected prior to the
complete installation of the product.
Remember, you do not want to damage
the product or jeopardize its structural
integrity.
Features
ISSUE • JULY – SEPTEMBER 2005
Bracing and stabilizing
Certain architectural and building application precast units may require temporary bracing to stabilize them against
loads like wind, seismic movement,
eccentric dead loads, incomplete connections, and possible impact from construction equipment or other precast
members. Bracing should already be
stored at the job site and readily available when needed.
Once a piece of precast is erected
and while the crane or boom still carries
the load, the bracing can be attached.
At the ground, bracing must be positioned to ensure that the unit remains in
the proper location. Most bracing can be
adjusted by turnbuckles, by changing its
position, or by other adjusting methods.
Bracing should not be removed until the
precast units are within the acceptable
placement tolerances and the permanent connections have been made.
Welding
Some precast component requires welding at their joints. Only certified welders should perform welding. All welders
should be competent personnel. Often it
is necessary to have connections welded
immediately after product placement.
It then becomes crucial that adequate
workspace is available for both parties
to work together without getting in
each other’s way or getting weld cables
wound around other gear.
Welds should be visually checked for
quality when complete. If the connections will be exposed to weather, they
and the weld should be coated with
a protective coating. Remember that
welding certain materials, such as galvanized metal, can be toxic and should be
avoided.
be required. A number of methods are
used for this. If dowels project up into
the precast, grout may be pumped in
through ports surrounding the dowels.
The grout is pumped into the bottom
port until it flows out of the top. This
ensures the removal of air voids. These
ports then need to be sealed with nonabsorptive stoppers. Dry packing is a
grout placement method used to fill
gaps or joints.
At the end of the day, workers should
tidy up work areas, clean up any messes, put away tools, and organize material and supplies for the next day if the
job is not complete. A brief production
meeting should be held to determine
the next day’s schedule, what supplies
and materials will be needed and which
ones have to be ordered. Having these
meetings will help workers work more
efficiently and feel more confident that
they know what’s required to achieve a
quality finished job.
Whether your precast products will
be underground or above ground, a
quality installation will be evident. Ontime, quality installations with a great
safety record will impress the parties involved in the construction and the owner, as well as build the esteem of your
installation crew. By achieving these,
your company will get the reputation it
deserves and also increase your chances
of getting the next job. You will also
help give the industry a good name.
Sources: MC Magazine 2001 – Precast
Installation Procedures
By Rofizlan Ahmad
Manager Construction Technology
Development Division
JOKE
Grouting
Grouting is done either prior to precast
placement or after. Grouting prior to
placement is usually for products that
incorporate cast-in dowels that slide
into predrilled holes or sleeves. Grout
mixtures should be placed just before
the units are installed into clean, prewetted holes. Pre-wetting prevents the
dry concrete from absorbing grout mixture water.
Once precast units are in their
proper location, further grouting may
IBSDIGEST 5
Features
ISSUE • JULY – SEPTEMBER 2005
Realising The Industrialisation
Of Malaysian Construction Industry:
CONSTRUCTION
IT PERSPECTIVE
INTRODUCTION
The construction industry is considered
as inefficient and highly labour intensive
activity. Conventional method using traditional brick and mortar give low and
inconsistency quality since workmanship
plays the main role, in which again relying on the skills of the labour. A study
done by Waleed et al. in 1997 stated
that, in order to achieve Malaysian plan
target using the present conventional
building system, it will require an excessive workforce, since on average only
one house is completed per year per
worker (one house/year/worker). Moreover, the required quality cannot be
achieved, because of poor quality control at the site. In order to overcome the
present problems, the mass production
of housing under high quality control is
required in which is the termed of Industrialized Building Systems (IBSs).
A pre-requisite for IBS is the adoption of Modular Coordination by all
parties from the submitting technical
consultants to the approving authorities. Modular Coordination is a concept
of coordination of dimension and space,
in which buildings and components are
dimensioned and positioned in terms of
basic units or modules, known as ‘1M’
which is equivalent to 100mm. It is internationally accepted by the World ISO
Standard and many other countries. In
Malaysia, Modular Coordination is hardly used in building design.
The main advantages of using IBS,
according to a report published by the
Malaysian Ministry for Local Government and Housing (Ministry 1997), are
speed of construction, quality, and economic advantage, all of which are required to meet such a large demand for
housing. In promoting the use of IBS
and MC, CIDB took a lead to role and
formulate a road map for improving the
construction output by addressing five
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IBSDIGEST
strategic issues including manpower,
materials, management, monetary and
marketing. This roadmap emphasised
the use of MC in achieving standardisation in the building industry and subsequently increasing the use of IBS components. While promoting the development and use of new and relevant technology in the process of nurturing construction industry players towards global
competitiveness, CIDB strongly insisted
the use of labour reducing systems in
order to reduce the reliance on foreign
labour in the local construction industry.
CONSTRUCTION IT
PERSPECTIVES ON IBS
In achieving the above challenge, CIDB
aims to develop an integrated MC-based
design system by the year 2007. However, several issues have to be resolved
at the earlier stage especially when involving the use of software applications
and the integration of these applications. For instance, the software applications of the IBS, which are concerned
with the data and information available
on the system, users, clients, establishment of manufacturing and assembly
layout and process, and allocation or
resources and material, have received
little attention. Therefore, there is a dire
need to overcome the shortage in the
software applications of the building
system research. Software applications
of the building system research utilize
accumulated technical knowledge and
the best technical foresight; this is in
order to improve building performance,
make building less costly to own, make
them safer to build and safer to live in,
build and use them with less waste of
resources and less pollution of the environment, and improve the quality of
private and public lives.
The greatest economy and efficiency
of construction can be achieved with a
minimum number of operations on site.
This includes minimizing assembling repetitive components, continuous process
and optimizing the start-stop activity.
Hence, a proper construction sequence
is required, not only for speeding-up the
construction, but also giving more advantages such as flexible solutions that
can help them to avoid collision in time
and space during the realization of a
project. This can be achieved by using
software application to analyze all phases of the future project at the planning
stage to anticipate any conflicts that
may occur and to elaborate on the optimal project scenarios. Traffic time on the
site can be kept to minimum by a computer system that schedules and monitor the time frame of deliveries through
specific gates and specific hoist4.
Extensive literature review indicates
that the above features stated above
currently either did not exist or did not
achieve to the expectations such as MC
Checker (MC2), in which will only checking the percentages of MC complaints
and the buildability of a design drawing
without the integration with the actual
design (architectural & structural). By
having an integrated design approach;
processing time and the cost of production can be optimized. JKR’s experience
also indicates the need of an integrated
design approach where it is a necessity
for design teams to work together in an
integrated approach from initial design
stage to optimize the design parameters
and avoid the time consuming to re-designs.
CONCLUSION
It is essential to have such an integrated MC-based system which will
demonstrates the potential of linking
the modern design and manufacturing
methods such as CAD/CAM, together
with systematic quality control and
project monitoring systems. By having
these features, a total solution for IBS
and MC-based design solution can be
achieved for improving the Malaysian
construction industry productivity and
output especially on realising the Government intention for making the Malaysian construction industry towards
industrialization.
By Dr. Che Wan Fadhil
Principle IT Consultant of EMOST Consult.
Features
ISSUE • JULY – SEPTEMBER 2005
IBS A SHORT HISTORY
INTRODUCTION
Prefabrication of building components
is not a new concept: Even the building
blocks of the great Egyptian pyramids
were prefabricated to the correct size at
the quarry to reduce the weight for the
transportation.
Traditional farm houses in Europe
were since the Middle Ages partly prefabricated and built in 3 feet modules
and the building industry in USA very
early planned to produce a kind of turnkey prefabricated timber houses as a
box system. But in UK the well known
Crystal Palace represents the first fully
dimensional coordinated, prefabricated
building system based on cast-iron components covered with a climatic screen
of glass.
The Crystal Palace from 1851 is
considered the ‘mother’ of all industrialized building systems: Extremely simple
layout and design based on a 24 feet
grid system and constructed of two materials: Cast iron and glass. The 72,000
square meter exhibition building was
designed and built in 6 months only, an
achievement that even today 154 years
later would be remarkable.
CONCRETE
Some years before the Crystal Palace
was built British engineers rediscovered
the method the Romans used to produce
‘Roman Cement’, a water proof plaster
that was made by burning volcanic ash
and lime stone together. The production
method was further developed into the
production of what we today call Ordinary Gray Portland Cement. The process
was kept as a strategic military secret
for some years but eventually the production method was generally known
and this new material spearheaded the
development of the contemporary industrialized building industry. The idea
of reinforcing concrete with embedded
steel came from a production of precast planter boxes in France. Thus the
most versatile construction material, reinforced concrete, was developed and
ready for use.
The abilities and properties of reinforced concrete was quickly explored
and new ways of design and calculation
developed for the main structure of cast
in situ building structures. By the end of
the 19th century claddings and decorative structural building components
were precast in what was called ‘reconstructed stone’ due to the strength and
durability of the components. As the
general industrialization of production
picked up speed in the 20th century
mass produced concrete components
became increasingly popular and the
technique of design and production further developed.
INDUSTRIALIZATION
Assembly belt production of cars in the
United States and the rationalized textile industry in the United Kingdom are
often proclaimed as forerunners for the
industrializing of the building sector. The
concept of planning, design and man-
agement for prefabrication and mass
production was already well developed
for other industries and ready to be
applied to the building industry. Large
scale prefabrication of major building
parts, such as walls, slabs and façade
components, started in countries which
had already obtained experiences from
industrializing other industries.
The real step forward for the prefabricated concrete housing technique
took place in Europe shortly after the
Second World War. It was a change in
people’s demands for housing and also
a change in family structure which influenced the building sector. People were
prepared and able to pay more for living
space and at the same time youngsters
wanted to move out from their parents’
home much earlier than before. This
created a demand for new housing that
the traditional construction method had
no possible way to satisfy.
The Building Authorities in many European countries, especially in Finland,
the Netherlands, France and Denmark,
realized that the only way to overcome
the lack of quality housing facilities due
to the increasing demand was to industrialize the housing production. Such a
concept would also ensure that a rapidly
growing building sector still could produce houses of high quality and at the
same time with an increasing productivity.
THE DANISH EXPERIENCE
In Denmark the implementation of
precast modular housing systems were
launched in 1958. In the first 9 years
IBSDIGEST 7
Features
from 1957-1967 the total number
of units build per year went up from
21,000 to 45,000, an increase of 115%.
At the same time the labor productivity in the building industry increased
with 75% and most of the work on the
building components was moved from
the construction site to the prefabrication factories. This meant higher salaries, job security and improved safety
and working conditions for the workers. As a consequence work in the construction industry became an ‘accepted
occupation’ and very little foreign labor
was needed in Denmark.
The reason for these impressive figures was mainly the fact that a clause
was added to the Danish Building Regulations saying: ‘Dwelling houses erected
for rental purposes shall be designed in
accordance with Modular Regulations
for Building Works’, as defined in Danish Codes. If the project was not modular designed it would not get a building
permission and since 85% of houses
built at that time were for rental purposes consultants were forced to learn how
to design modular building projects.
With this clause it was mandatory to
produce modular designs but still voluntary to use prefabricated components or
ISSUE • JULY – SEPTEMBER 2005
or less dictated the shape of the precast
buildings. The Architects at first found
it below their ‘dignity as artists’ to deal
with structure and buildability and was
consequently left with only the outer
2-4 mm façade skin to play with in
design for patterns, profiles and color.
This created many boring buildings and
gave Precast a bad reputation as a low
cost and ‘boxy’ design and construction
suited for cheap mass housing only.
CONCLUSION
The conditions in Europe, USA and Australia for the design of precast buildings
have now changed and the Architects
have won back the role as the leader
of the precast design team by learning
JOKE
Engineers and Lawyers
not. But very soon the modular design
condition had a great impact on the entire construction industry in the country.
As most projects were now prepared for
the use of modular slab components and
walls with standard design a new market was created. It now became tempting and economical viable for contractors and investors to establish factories
for producing precast components for
especially residential buildings.
In the very beginning the Precasters and the Structural Engineers more
8
IBSDIGEST
On a college field trip, four Engineering and four Pre-Law students
were travelling on the same train.
The law students each had a ticket, but the Engineers had but one
ticket amongst them. One of the
Engineers shouted “conductor’s
coming!”, and the four Engineers
crowded into one of the bathrooms.
The conductor comes by and knocks
on the bathroom door saying “Tickets, please”. The Engineers slip their
one and only ticket under the door.
how to adapt the precast construction
method in the design. Developers of
precast buildings surely have recognized
the benefit of implementation of the
‘integrated design concept’, meaning a
strong corporation between Architects,
Structural and Mechanical Engineers,
Precasters and Contractors from the
very first stage of the design. For many
years now durable and pleasant looking buildings have been designed and
implemented using prefabrication technology both for load bearing structures
and for claddings. The benefits of using
Industrialized Building Systems are now
appreciated by clients all over the world:
Higher quality, faster construction time,
reduction in labor force, higher productivity, reduction in costs and less maintenance.
The development of the building industry in Malaysia towards industrialization and prefabrication has just picked
up speed with the government’s drive
for ‘Industrialized Building System’, IBS
through CIDB and other channels. Seen
with the experience from the rest of the
industrialized world developers, contractors and consultants in Malaysia have no
choice but to look forward and prepare
their projects for IBS.
by Poul Bannow Mork, IBS Alliance Sdn Bhd
The conductor punches it an moves on
to the next car.
On the return trip, the four Lawyers,
impressed by the Engineers’ trick, purchase only one ticket. The Engineers,
however have no tickets at all!. Suddenly, one of the Engineers shouts
“Conductor’s coming”. All four Engineers head for the bathroom, and all
four lawyers crowd into the other one.
Then, one of the Engineers slips out
of his bathroom and knocks on the
other bathroom door saying “Tickets,
please”. The lawyers then slip their
only ticket under the door, and the
Engineer then picks up the ticket and
joins his friends, waiting for the real
conductor.
Features
ISSUE • JULY – SEPTEMBER 2005
Soalan-soalan
Yang Seringkali Ditanya (FAQs) Mengenai Sistem
Binaan Berindustri (IBS) dan Kordinasi Modular (MC)
Apakah IBS?
Sistem Binaan Berindustri (IBS) juga dikenali sebagai pembinaan pasang siap: sistem pembinaan di mana
komponen diperbuat di kilang, di tapak atau di luar tapak, diangkut dan kemudian dipasang menjadi
sebuah struktur dengan kerja yang minimum. Lima jenis IBS yang biasa digunakan di Malaysia adalah
sistem kerangka panel dan kekotak konkrit pratuang, sistem kerangka keluli, sistem kerangka kayu prasiap, sistem acuan keluli serta sistem blok pratuang.
Apakah Manfaat
Menggunakan IBS?
Manfaat utama yang diperolehi melalui
penggunaan sistem ini adalah seperti
berikut:
• Produk yang berkualiti tinggi dan
pembaziran yang minimum kerana
persekitaran kerja di kilang lebih
mudah dikawal;
• Penghapusan acuan kayu
konvensional dan pengurangan
ketara penggunaan penyangga
melalui penggunaan elemen
pasang siap atau sistem acuan bagi
proses tuangan di tapak;
• Platform kerja yang teguh dan
selamat dihasil melalui elemen
pasang siap;
• Penyiapan yang lebih cepat
berikutan pengenalan komponen
yang menggantikan pembinaan insitu;
• Tapak pembinaan lebih teratur,
bersih dan selamat berikutan
pengurangan sampah binaan,
pekerja dan bahan binaan ditajak;
• Jumlah kos pembinaan yang lebih
rendah berikutan manfaat yang
dicapai daripada faktor-faktor di
atas.
Poster Promosi IBS sering
menyatakan bahawa
penggunaan kaedah IBS dapat
mengurangkan kos projek.
Tetapi melalui pengalaman
saya, tidak. Sila ulas.
Jika anda membandingkan hanya kos
bahan sahaja, memang benar komponen IBS adalah lebih tinggi berbanding
kos in-situ. Pengilang IBS perlu membelanjakan sejumlah wang yang besar
untuk mendirikan kilang dan dengan
demikian perlu menyerapkan kos pelaburannya ke dalam harga produk IBS.
Walau bagaimanapun, sama seperti
produk pengguna lain, kita memang
perlu membayar harga yang lebih tinggi
untuk mendapatkan jenama bertaraf
premium. Dalam pembinaan, IBS adalah
sebuah jenama premium kerana ia
menawarkan kualiti, produktiviti dan
tahap keselamatan yang lebih terjamin. Oleh itu sudah semesti harganya
lebih tinggi sedikit. Di samping itu, kita
perlu melihat kepada manfaat di dalam
penggunaan kaedah IBS. Dengan penggunaan kaedah IBS, ia memberi kualiti
yang lebih baik maka kos kerja pembaikpulih dapat dikurangkan. Masa membina yang lebih pendek juga bermakna
pulangan daripada pelaburan (ROI) boleh dicapai dengan lebih pantas. Bagi
pembeli rumah, ia bermakna mereka
boleh mengelak daripada membayar
lebih banyak faedah kepada bank. Bagi
para pemilik kilang atau pejabat pula,
mereka boleh memulakan operasi den-
gan lebih cepat. Jika dilihat dari sudut
yang lebih luas lagi, bayangkan betapa
Kerajaan boleh menjimatkan wang berbilion Ringgit dengan mengurangkan
pergantungan kepada pekerja asing
dan pengaliran keluar matawang Ringgit ke negara luar.
Saya Tidak Yakin Terhadap
Prestasi Struktur Bangunan
Yang Dibina Menggunakan
Kaedah IBS. Adakah Bangunan
Tersebut Seteguh Struktur
Binaan Konvensional?
Saya Juga Masih Ragu Cara
Pembinaan Ini Boleh Menjamin
Tiada Kebocoran.
IBS hanya merupakan kaedah pembinaan sahaja. Rekabentuk sebenarnya
menentukan keteguhannya, sama seperti struktur konvensional. Perbezaannya adalah struktur IBS memerlukan
pengiraan tambahan bagi peringkat
pembinaan. Bangunan yang dibina
menggunakan kaedah IBS juga mempunyai prestasi struktur yang serupa seperti keteguhan bangunan yang dibina
mengikut kaedah tuang-in-situ. Perincian keluli pada sambungan IBS juga
merujuk kepada asas yang sama seperti
yang ditetapkan dalam kod rekabentuk. Sebagai contoh, Papak Separuh
konkrit pratuang 65mm dengan tuangan tambahan konkrit in-situ 75mm
IBSDIGEST 9
Features
akan mempunyai keteguhan struktur
yang sama dengan papak konkrit tuang-in-situ 140mm selagi ia direkabentuk dengan kod rekabentuk dan menggunakan beban dan bahan yang sama.
Beberapa bangunan IBS yang terawal
dibina di Malaysia mungkin pernah
menggunakan sambungan kering yang
berkecenderungan untuk bocor dengan
mudah berbanding sambungan. Walau
bagaimanapun, kebocoran sebenarnya
tiada kaitan dengan sistem IBS, tetapi
sebaliknya adalah berkaitan dengan hasil kerja yang tidak memuaskan. Tanpa
melakukan kerja konkrit dan kerja kalis air dengan sempurna, pembinaan
tuang-in-situ juga boleh berlaku kebocoran. Sungguhpun diperbuat dengan
tahap kualiti paling tinggi, komponen
Completely Knocked Down (CKD)
kereta Mercedes Benz sekalipun akan
mengalami kegagalan sekiranya kerja
pemasangan tidak dilakukan mengikut
prosedur yang betul;
Apakah Kordinasi Modular?
Adakah Ia Merupakan Satu
Lagi Teknik Pembinaan?
Kordinasi Modular atau MC adalah
sebuah sistem dimensi. Ia merupakan
konsep koordinasi dimensi dan ruang di
mana bangunan dan komponen di letakkan kedudukannya berasaskan kepada unit atau modul asas dikenali sebagai
‘1M’ yang bersamaan dengan 100mm.
Sebagai contoh, daripada menggunakan ukuran 2413mm, yang lebih sukar diukur, ia akan digenapkan kepada
2400mm. Penggunaan MC adalah satu
faktor penting dalam aplikasi IBS secara berkesan kerana ia melengkapkan
pengindustrian melalui pempiawaian
dan peningkatan produktiviti.
Adakah Kita Mempunyai
Standard Malaysia (MS) Bagi
MC Dan Di Mana Saya Boleh
Dapatkannya?
MS bagi MC dipanggil MS 1064 (Panduan Kepada Koordinasi Modular
dalam Bangunan). Ia mengandungi 10
bahagian dan berasaskan kepada stan-
10
IBSDIGEST
ISSUE • JULY – SEPTEMBER 2005
dard ISO yang diiktiraf di peringkat antarabangsa. Anda boleh membelinya
daripada SIRIM Berhad, ejen yang dilantik oleh Jabatan Standard Malaysia
(DSM) untuk membangun, mengedar
dan menjual Standard Malaysia.
Adakah Benar Bahawa
Dengan Menggunakan MC,
Kita Menghadkan Bangunan
Kepada Bentuk Empat Persegi
Sahaja?
Tidak benar sama sekali. Ia bergantung
kepada daya kreativiti dan pilihan perekabentuk. Rekabentuk kuarters JKR
yang dibina menggunakan ukuran MC
dan kaedah IBS adalah buktinya. Begitu
juga dengan beberapa rekabentuk bangunan lain yang dibina di negara maju
seperti Perancis, Singapura, Denmark
dan Finland; Sebenarnya, kebanyakan
bangunan awal yang dibina menggunakan MC dan IBS adalah bangunan
yang dibina sekitar tahun 1960an, berikutan program pembangunan semula
selepas zaman perang yang dilakukan
dengan pesat. Pada masa itu, rekabentuk seni bina minimalis menjadi pilihan;
dan dengan demikian wujudlah banyak
bangunan berbentuk empat persegi dan
fasad yang minimal.
Bagaimana MC Digunakan
Bagi Rekabentuk Rumah
Teres? Ini Kerana Tapak Tanah
Telah Dibahagikan Kepada
Bahagian Yang Lebih Kecil
Berasaskan Kepada Ukuran
Imperial.
Di samping menggalakkan penstandardan dan produktiviti, MC telah dibangunkan oleh ISO bagi mempermudah
penukaran dimensi Imperial kepada
Metrik. Panduan bagi penggunaan MC
di tapak yang dibahagikan kepada beberapa tapak kecil disediakan dalam
“Modular Coordination Notes; Implikasi
Koordinasi Modular Dalam Undang-undang dan Peraturan Bangunan” dan
“Modular Design Guide”.
Adakah Sebarang Latihan
Mengenai IBS dan MC
Disediakan?
Ya, kami mempunyai sesi latihan secara
kerap untuk rekabentuk konkrit pratuang serta MC. Kami juga merancang
untuk memulakan kursus rekabentuk
keluli. Sila hubungi kami melalui e-mel
di [email protected] bagi mendapatkan
maklumat terkini.
Saya Dengar Dalam Ucapan
Bajet 2005, Projek Perumahan
IBS Dikecualikan Daripada
Membayar Levi CIDB. Adakah
Fakta Ini Benar?
Projek perumahan dengan kandungan
IBS (IBS Score) yang minimum iaitu sebanyak 50% akan diberi pengecualian oleh CIDB daripada membayar levi.
Panduan bagi pengiraan IBS Score disediakan dalam penerbitan: Manual for
IBS Content Scoring System (IBS Score).
Sila hubungi Unit Levi di talian 03-2617
0200 bagi mendapatkan keterangan
lanjut mengenai permintaan untuk
mendapatkan pengecualian levi.
Di Manakah Saya Boleh
Mendapatkan Bahan Rujukan
Mengenai IBS dan MC?
Kami menawarkan pelbagai jenis penerbitan mengenai IBS dan MC. Ini termasuk Standard Industri Pembinaan,
katalog produk, manual dan prosiding.
Anda boleh membelinya dari semua
Pejabat CIDB Negeri atau Wilayah serta
dari kaunter di Tingkat 7, Ibu Pejabat
CIDB di Kuala Lumpur. Beberapa penerbitan lain juga tersedia untuk dimuat
turun secara percuma daripada laman
web kami di: www.cidb.gov.my
Ir. Shahrul Nizar Shaari
Pengurus, Bahagian Pembangunan
Teknologi, CIDB Malaysia.
News
ISSUE • JULY – SEPTEMBER 2005
Program Promosi
IBS WILAYAH
SABAH
Malaysia, Latihan Kordinasi Modular
dan Latihan Rekabentuk Konkrit Pra
tuang serta pameran mini produk IBS
yang terdapat di pasaran.
Program ini bertujuan untuk menggalakkan pembinaan secara berindustri
sebagai satu alternatif kepada kaedah
konvesional (insitu), melalui IBS dan MC
khusus kepada semua peserta industri
pembinaan seperti penggubal dasar,
agensi pelaksana, pemaju, perekabentuk, pengilang, kontraktor, pembekal,
penyelidik dan pihak-pihak lain yang
terlibat.
Dengan adanya program ini tahap
kualiti, produktiviti, keselamatan dan
pergantungan berlebihan kepada pekerja asing yang tidak mahir dapat
diperalaskan dengan pembangunan
masa depan Malaysia. Seperti yang
dinyatakan di dalam Ucapan Bajet
2005 dengan menguatkuasakan penggunaan IBS di dalam projek bangunan
kerajaan dan pengecuali levi CIDB untuk projek IBS. Program ini telah turut
memaparkan latarbelakang program
IBS, Roadmap IBS dan kajian kes mengenai penggunaan IBS di Malaysia. Di
CIDB telah mengadakan program Road-
trikan sektor pembinaan Malaysia. Pro-
show IBS yang ke 4 di Wilayah Sabah
gram ini merangkumi Seminar ke arah
pada 19 hingga 21 Julai 2005 bagi
Mengindustrikan Industri Pembinaan
samping itu turut diadakan mengenai
penentuan kandungan IBS di dalam sesuatu projek melalui Manual IBS Score.
memberi kesedaran awal tentang Indutrialised Building System (IBS) dan Kordinasi Modular (MC). Program tersebut
telah dirasmikan oleh Y.B Datuk Raymond Tan Shu Kiah, Menteri Pembangunan Infrastruktur Sabah. Seramai 130
peserta daripada sektor kerajaan dan
swasta telah menghadiri program tersebut. Program ini telah diadakan di Hyatt
Regency Kinabalu, Kota Kinabalu. Ia
merupakan salah satu daripada aktiviti
promosi yang telah dirangka di bawah
Roadmap IBS 2003-2010 yang telah
disahkan oleh kabinet sebagai satu dokumen pelan induk untuk mengindus-
IBSDIGEST 11
Announcements
ISSUE • JULY – SEPTEMBER 2005
Promosi Sistem Binaan
Berindustri (IBS) Sarawak
•
•
•
Seminar
Kursus Koordinasi Modular
Kursus Rekabentuk Konkrit Pratuang
PROMOSI SISTEM BINAAN BERINDUSTRI (IBS)
WILAYAH SARAWAK
KE ARAH PEMBINAAN BERKUALITI DAN PENGURANGAN PERGANTUNGAN TENAGA BURUH
26 – 28 SEPTEMBER 2005
HOLIDAY INN, KUCHING
Dirasmikan oleh
YB Dato Sri Abang Haji Abdul Rahman Zohari Bin Tun Abang Haji Openg
Menteri Perumahan Sarawak
Dianjurkan oleh:
Lembaga Pembangunan Industri Pembinaan Malaysia
Disokong oleh:
Kementerian Perumahan
Sarawak
12
IBSDIGEST
Sarawak Housing
Developer Association
PKMM
Sarawak
IEM
Sarawak Branch
PAM
Sarawak Chapter