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INDUSTRIALISED BUILDING SYSTEM VERSUS CONVENTIONAL SYSTEM

IN WASTE PRODUCTION TOWARD SUSTAINABILITY IN CONSTRUCTION

NOOR ASYIQ BINTI MOHD JOHAR!

A thesis submitted in partial fulfillment of the requirements for the award of the

degree of Bachelor of Civil Engineering with Environment

Faculty of Civil Engineering & Earth Resources

University Malaysia Pahang

JUNE 2012

iv

ABSTRACT

Industrialised Building System (IBS) is a system where buildings are reduced to a number of common parts, where most of it can be prefabricated in long term production runs, frequently away from the construction site. Lately, Malaysia government strongly support the usage of IBS in construction industry due to its quality assurance, shorter construction period, cleaner site condition, safer working environment and reduction in labour dependency. In this study, the advantage of IBS is focused on the reduction and management control of wastes, or basically minimizing wastes at the construction site which lead to sustainability in construction. Efforts to make IBS a success are not sufficient without the participation and support from the private sector. Questionnaire surveys were undertaken throughout the industry role players such as developer, consultant, contractor and government bodies. The analysis result showed that the involvement of the respondents in IBS was high and the awareness level was also considerably high. The use of steel in the conventional construction create the most waste and by using IBS the saving in material amount to approximately 54.83%. On the other hand, the set of timber does not show any significant material savings in either the conventional or IBS construction.

v

ABSTRAK

Sistem Binaan Berindustri (TBS - Industrialised Building System) merupakan sistem dimana struktur bangunan diringkaskan kepada beberapa bahagian ringkas dan mudah yang mana ia boleh direkabentuk dan diproses bagi pembuatan produk untuk jangkamasa yang panjang dan berterusan, jauh daripada tapak binaan. Kebelakangan ini, kerajaan Malaysia begitu menyokong penggunaan IBS dalam industri binaan terutamanya dari segi kawalan kualiti, jangkamasa binaan yang singkat, keadaan tapak yang bersih, persekitaran kerja yang seJamat dan juga pengurangan dalam keperJuan buruh. Dalam kajian ini, kebaikan pengunaan IBS dalam industri binaan difokuskan kepada pengurangan dan pengawalan sisa bahan binaan, pada amnya meminimumkan pembaziran di tapak bina yang akan menjurus kepada konsep pembinaan yang mapan. Usaha bagi menjayakan pengunaan IBS tidak akan terlaksana tanpa penglibatan dan sokongan daripada sektor swasta. Kajian secara soal selidik telah dilakukan dikalangan pihak yang terlibat dalam industri binaan seperti pemaju, perunding, kontraktor dan juga badan-badan kerajaan. Hasil analisis menujukkan bahawa penglibatan responden dalam penggunaan TBS adalah agak tinggi dan diutamakan. W alaubagaimanapun, tahap kesedaran tentang kebaikan dan keberkesanan IBS dalam industri binaan amat memberansangkan. Penggunaan besi dalam sistem binaan konvensional menghasilkan peratus sisa yang paling tinggi tetapi dengan adanya penggunaan ms, pembaziran bahan binaan tersebut boleh dikurangkan sehingga lebih kurang 54.83%. Sebaliknya, penggunaan bahan berasakan kayu tidak menunjukkan penjimatan yang ketara dalam kedua-dua sistem konvensional dan IBS.

CHAPTER

1

2

TABLE OF CONTENTS

TITLE

THESIS STATUS VALIDATION FORM

SUPERVISOR'S DECLARATION

TITLE PAGE

STUDENT'S DECLARATION

ACKNOWLEDGEMENT

ABSTRACT

ABSTRAK

TABLE OF CONTENTS

LIST OF TABLES

LIST OF FIGURES

LIST OF SYMBOLS

LIST OF APPENDICES

INTRODUCTION

1.1. Introduction

l.2. Problem Statement

1.3. Objectives of Study

1.4. Scope of Study

1.5. Significant of Study

LITERATURE REVIEW

2.1. Introduction

2.2. Sustainable Building

2.2.l. Definition of sustainability

VI

PAGE

11

lll

iv

v

vi

x

xi

xiii

XIV

I

2

2

3

3

4

4

4

vii

2.2.2. Sustainable Development 5

2.2.3. Environmental sustainability 6

2.2.4. Sustainable construction 7

2.3. Industrialised Building System (JBS) 8

2.3.1. Definition of IBS 8

2.3.2. Background of IBS 9

2.3.3. Characteristic of IBS 10

2.3.4. TypeofTBS 10

2.3.5. Advantages of ms 11

2.3.5.1. High quality and aesthetical value of 11

products

2.3.5.2. Cleaner and safer construction sites 11

2.3.5.3. Faster construction 12

2.3.5.4. Greater unobstructed span 12

2.3.5.5. Lower total construction costs 12

2.3.6. Successful implementation of ms projects 13

2.4. Conventional System 15

2.4.1. Definition of conventional system 15

2.4.2. Conventional system characteristic 16

2.4.3. Advantages and disadvantages of conventional 16

system

2.5. Construction Waste 17

2.6. Deconstruction/ Demolition Waste 19

2.7. The Disposal of Construction and Demolition Wastes 19

3 RESEARCH METHODOLOGY

3.1. Introduction 20

3.2. Phase of Research Methodology 20

3.2.1. Phase 1: Identification scope of study 21

3.2. l. l. High quality and aesthetical value of 21

products

3.2.2. Phase 2: Data collection (development of 21

questionnaire)

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3.2.3. Phase 3: Data analysis 22

3.2.4. Phase 4: Conclusion 23

3.3. Summary 23

4 ANALYSIS AND RESULT

4.1. Introduction 24

4.2. Analysis of Construction Material Waste for 25

Conventional System Versus IBS

4.2.1. Wastage level of steel 27

4.2.2. Wastage level of brick 28

4.2.3. Wastage level of timber 30

4.2.4. Wastage level of cement 31

4.2.5. Wastage level of tile 33

4.2.6. Wastage level of glass 34

4.2.7. Wastage level of soil 36

4.2.8. Wastage level of concrete 37

4.2.9. Wastage level of other (sand, gravel) 39

4.2.10. Average wastage in conventional and IBS 40

construction

4.2.11. Wastage Comparison between IBS and 42

Conventional System

4.3. Analysis of Awareness and Advantages ofIBS 44

Implementation

4.3.1. Results of awareness and advantages of JBS 45

implementation

5 CONCLUSION

5.1. Introduction 48

5.2. Waste Level in Conventional and TBS Construction 49

5.3. The Awareness on JBS Advantages Among The Players 49

5.4. Recommendations 50

REFERENCES 51

IX

APPENDIX A 52

TABLE NO.

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

LIST OFT ABLES

TITLE

Number of Questionnaire Returned

Frequency of Wastage Level in Conventional Construction

Frequency of Wastage Level in IBS Construction

Wastage Level of Steel in Conventional and JBS Construction

Wastage Level of Brick in Conventional and JBS Construction

Wastage Level of Timber in Conventional and IBS

Construction

Wastage Level of Cement in Conventional and !BS

Construction

Wastage Level of Tile in Conventional and IBS Construction

Wastage Level of Glass in Conventional and IBS Construction

Wastage Level of Soil in Conventional and JBS Construction

Wastage Level of Concrete in Conventional and lBS

Construction

Wastage Level of Other in Conventional and IBS Construction

Average Wastage of Conventional System & IBS and

Percentage of Reduction of Wastage Level

The Advantages ofIBS Implementation

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PAGE

25

26

26

27

28

30

31

33

34

36

37

39

40

45

TABLE NO.

2.1

2.2

2.3

2.4

2.5

2.6

4.1

4.2

4.3

4.4

4.5

4.6

4.7

4.8

LIST OF FIGURES

TITLE

Industrialised Building Systems (IBS)

Sultan lskandar Custom, Immigration & Quarantine Complex,

Johor Bharu

Persada Johor International Convention Centre, Johor Bharu

Aeon Jaya Jusco Tebrau Shopping Complex, Johor Bharu

Kuching International Airport Terminal Building, Sarawak

Percentage of Construction Waste Chart (Green Building Source)

Percentage of Frequency versus Wastage Level of Steel

Percentage of Frequency versus Wastage Level of Brick

Percentage of Frequency versus Wastage Level of Timber

Percentage of Frequency versus Wastage Level of Cement

Percentage of Frequency versus Wastage Level of Tile

Percentage of Frequency versus Wastage Level of Glass

Percentage of Frequency versus Wastage Level of Soil

Percentage of Frequency versus Wastage Level of Concrete

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PAGE

8

13

14

14

15

18

27

29

30

32

33

35

36

38

xii

4.9 Percentage of Frequency versus Wastage Level of Other 39

4.10 Average Wastage for 9 Materials in Conventional And IBS 41

4.11 Percentage of Waste Reduction for 9 Materials by Using IBS 42

4.12 Construction Waste in Conventional Construction 43

4.13 Construction Waste in JBS Construction 44

4.14 Frequency of Awareness and Advantages of IBS Construction 46

xiii

LIST OF SYMBOLS

a Constant

x Variable

1,2,3 .. . . n

x Mean

x Median

f Frequency

LIST OF APPENDICES

APPENDIX TITLE

A Questionnaire

xiv

PAGE

52

1

CHAPTERl

INTRODUCTION

1.1 Introduction

The Construction Industry plays an important role for growth of the Malaysia

economy, which contribute about 2.9% of gross domestic product (GDP) in year

2010. However, it was one of the industries that contribute to high waste level in

Malaysia. The conventional construction practices (basically cast in-situ where the

entire structural components are cast on site) nowadays generated high level of

waste.

Thus, the government has supported changes in the construction industry

which bring development to the country. On 2007, the Prime Minister in his speeches

at CIDB conventions stated that " Malaysia as a rising country which has most of the

first world countries technologies, should not just bear the name of Advanced in

Technology, but also has the mindset of the developed countries, which is to

implement development. One of the ways that are quite reachable is through the

construction industry which is Industrialized Building System (IBS), where it is the

main attraction for construction player to have rapid, economic, safe, and free of

wastage environment which lead to sustainable construction."

The demand of the building construction in Malaysia had increase rapidly

from year to year together with the established of IBS as one of method of

construction. This method is growing to lead more local manufactured established

2

themselves in the market. Industrialised Building System (IBS) is define as complete

assembly construction system where components are manufactured at factories on or

off site, transported and then assembled into a structure with minimum work. It is

consider as better solution to reduce construction waste because it not only help

reduce the total construction costs as well as faster the project completion, but it also

has higher reduction of on-site labor, lower wastage, less site materials, and cleaner

environment.

1.2 Problem Statement

Construction industry consume substantial amount of raw material in the

process which generate product and also the construction waste material. In

conventional system of construction, generally a total of 30% construction waste is

generated and 60 - 80% of the waste can be reused and recycled. The waste such as

timber, steel, plastic, concrete, and glass can actually be reused and recycled, but

unfortunately they usually dumped and will lead to wastage of construction material

which contributed to environment pollution.

1.3 Objectives of Study

i. To identify and compare the generated construction waste in di·fferent

waste in different construction material between Industrialised Building

System and conventional system.

11. To study the awareness on sustainability in construction among the players

in construction industry.

iii. To study the advantages of IBS in minimizing waste as an important

criteria in sustainable construction.

3

1.4 Scope of Study

This study mainly focused on construction waste which becomes a problem

towards the environment. To identify the efficiency of the IBS in minimized the

generated construction waste, the comparison between the conventional method and

IBS method were carried out. Data was collected mainly from the questionnaire

survey which distributed to construction player such as client, consultant, contractor

and construction workers who have experience in both type of construction method.

1.5 Significant of Study

This study was done to give awareness among the construction players on the

advantages of using IDS method to improve on waste management, which is very an

important criterion to a sustainable construction.

4

CHAPTER2

LITERATURE REVIEW

2.1 Introduction

The objective of this research is to evaluate the performance of Industrialised

Building System (IDS) in minimizing construction waste which is one of the aspects

that has to be fulfilled to achieve the sustainable concept. The IBS is to be compared

with conventional system in term of construction waste generated on site.

In this chapter, definition and description of sustainability, sustainable

development and sustainable construction are given. IBS and conventional system of

construction are described in detail and construction waste generated during the

process of construction and demolition are also reviewed.

2.2 Sustainable Building

2.2.1 Definition of sustainability

Sustainability, according to Webster' s American Heritage Dictionary, is to

keep in existence; maintain. Sustainability which relates to our life means meeting

our present needs without compromising the needs of the future generations. The

sustainable approach recognizes the interaction of natural and technological systems

5

on our planet and seeks to minimize the adverse impacts in our everyday lives on the

system that support aJl life.

The implication of the sustainability is to understand our local environment in

terms of climate, natural resources and human resources to improve the relationship

with these aspects without jeopardizing their future usefulness. Recognizing and

understand the nature of the interdependence of human and natural environment is

the key concept towards understanding sustainability. A sustainable approach

encourages people to become a part of the natural flows and cycles of our world and

not seeking to overpower them.

2.2.2 Sustainable development

The concept of sustainable development was first proposed by the World

Commission on Environment and Development (WCED) which Jed by the

Norwegian Prime Minister, Gro Harlem Brundtland in 1972 as "Meeting the needs of

the present without compromising the ability of the future generations to meet their

own needs". However, this definition has evolved since then.

During the United Nation Earth Summit held by the United Nations

Environment Programmed (UNEP) in Rio de Janeiro (1992), sustainable

development was defined as "Improving the quality ofhuman·Iife while living within

the carrying capacity of supporting eco systems". This definition has an impact on

the economic, social and environmental development and was later formaJJy adopted

worldwide. Sustainable development is not a fixed state of harmony, but rather a

process of change in which the exploitation of resources, the direction of

investments, the orientation of technological development and institutional changes

are made consistent with future as well as present needs.

The word development in this definition implicates two major aspects of the

concept: it is omnidisciplinary, it cannot be limited to a number of disciplines or

areas, but it is applicable to the whole world and everything on it including human

6

being in present and future. The definition is based on two concepts which are the

need concept and the limits concept. The need concept comprises of the conditions

for maintaining an acceptable life standard for all human being while the limits

concept is the limitation in the capacity of the environment to fulfill the needs of the

present and the future, determined by the state of technology and social organization.

The needs consist firstly of basic needs such as food, clothing, housing and

employment. Secondly, every individual in very part of the world should have the

opportunity to try and raise their life standard above this absolute minimum. The

limits consists of natural limitations such as finite resources which also includes of

declining productivity caused by overexploitation of resources, decJining quality of

water and shrinking of biodiversity. For the best of the future, the needs should be

fulfilled while the limits preferably decreased. If the needs and the limits are

fulfilled, this would lead to the conclusion that all political, technical and social

developments can easily be evaluated in the scope of sustainable development by

these two arguments.

2.2.3 Environmental sustainability

The idea of environmental sustainability is to protect the Earth so that it will

always be in the best condition for the future generations. By a definition, human

activity is considered as environmental sustainable when it can be performed of

maintained indefinitely without depleting natural resources or degrading the natural

environment. These activities include:

• Minimum consumption of resources.

• Minimum production of waste (construction waste).

• Recycling of the waste streams would be 100%.

• Energy would be conserved and energy supplies would be entirely

renewable and non-polluting.

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• Materials consumed would be made entirely of 100% post-consumer

recycled materiaJs or from renewable resources (which do not harm the

environment and without depletion of the resource base).

2.2.4 Sustainable construction

Sustainable construction was first defined by Kibert (1994) as '"the creation

and responsible management of a healthy built environment based on resource

efficient and ecological principles". Sustainable designed buildings aim to lessen

their impact on the environment through energy and resource efficiency. It includes

the following principles: minimizing non-renewable resources consumption;

enhancing the natural environment; eliminating or minimizing the use of toxins.

The inclusion of construction in sustainable development was proposed at the

Jast World Summit for SustainabJe Development held in Johannesburg in September

2002. Inspired of the various definitions, the aim and goals of sustainable

construction remain the same. Sustainable construction is a way for the building

industry to move towards achieving sustainable development, taking into account

environment, socioeconomic and cultural issues.

The concept of sustainability in building and construction has initially

focused on issues of limited resources, especially energy, and how to reduce impacts

on natural environment with emphasis on technical issues such as materials, building

components, construction technologies and energy related design concepts. One of

the methods to reduce impacts on natural environment is to minimize both

construction and deconstruction waste production. This can be achieved by the using

lBS in construction besides the other method such as recycling or reusing of

construction waste.

8

2.3 Industrialised Building System (IBS)

2.3.1 Definition of IBS

IBS stands for Industrialised Building System. There are few definitions of

JBS according to few researchers. JBS can be defined as those incorporating a total

integration of all subsystems and components into an overall process; one fully

utilizing industrialized production, transportation and assembly techniques (Albert

1970). Funher from there, IBS utilizes techniques, products, components or building

systems which involved prefabricated components and on-site installation.

According to CIDB Malaysia, IBS may 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". It is a construction

system that is built using pre-fabricated components. The manufacturing of the

components is systematically done using machine, formworks and other form of

mechanical equipment. The components are manufactured off-site and once

completed will be delivered to the construction sites for assembly and erection.

Figure 2.1: Industrialised Building Systems (IBS)

It is interesting to note that the term "Industrialised Building Systems" (IBS)

is often misinterpreted as systems limited only for the construction of buildings. In

fact, IBS covers all types of structures as the word "building" actually relates to

"constructing". (Shaari and Elias, March 2003).

9

2.3.2 Background of JBS

Industrialised construction system is not new to the building industry. The

first panelized wood house in India was shipped from England in 1624 to provide

temporary housing for fishing fleet.

Industrialised building systems have been used in construction industry in

Malaysia for quite some time. Most of the systems which are marketed locally

promise better quality, faster speed and more cost effective construction compared to

the conventional approach of construction which local builders are so used to and

quite reluctant to depart from. However past and recent experiences in the use of a

few building systems in the country and abroad have suggested a need to carefully

assess the systems that are being introduced in the country. This is necessary to

ensure that the systems are suitable to the need of the Malaysia construction industry.

The use of TBS in Malaysia started back in 1963. fn 1966 and 1967, the first

two projects constructed using IBS method were the construction of 3009 unit of

flats-accommodation in Jalan Pekeliling, Kuala Lumpur and 3741 units in Jalan

Padang Tembak, Pulau Pinang. The success of JBS method in the country can be

observed from the many structures built from the year 1995 to 1998. Such example is

the Petronas Twin Tower, LRT and Kompleks Sukan dan Perkampungan Sukan

Bukit Jalil. The JBS are also implemented in the construction of multiple-storey

highway and monorail transit track that used pre-cast beam.

Though it has been four decades since the introduction of TBS in Malaysia,

the application of this method in local construction industry is still low compared to

developed countries such as Australia, United State, United Kingdom and Japan.

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2.3.3 Characteristic of IBS

Systems to be accepted as part of IBS need to possess alJ characteristic

below, as all of the five are equally important to ensure the achievement of the

claimed benefits. The five characteristics of IBS are (Shaari and Elias, March 2003):

• Industrial production of components though prefabrication; or highly

mechanized in-situ processes i.e. slip-forms, post- tensioning, tunnel

shutters.

• Reduced labor during prefabrication of components and site works.

• Modem design and manufacturing methods i.e. involvement of Computer

Aided Design (CAD) and Computer Aided Manufacturing (CAM).

• Systematic Quality Control i.e. lSO 9000 principles.

• Open Building Concept i.e. permitting hybrid applications, adaptable to

standardization and Modular Coordination (MC).

2.3.4 Type of ms

The Malaysian construction industry is undergoing a transitional change from

an industry employing conventional technology to a more systematic and

mechanized. In this system, ms can be divided into five major types based on the

structural aspects (Shaari and Elias, March 2003) as stated below;

• Precast Concrete framing, Panel and Box Systems

• Steel Formwork Systems

• Steel Framing Systems

• Prefabricated Timber Framing Systems

• Blockwork Systems

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2.3.5 Advantages of IBS

Advantages of IBS technology in the construction of commercial, residential

and institutional building are well documented literature. It is commonly

acknowledge that IBS technology has tremendous potential towards productivity

improvement as it encompasses aspects of standardization, high controlled and

quality ms components which complements the various program to increase

productivity and quality in construction industry.

2.3.5.1 High quality and aesthetical value of products

IBS products are manufactured in a casting area where critical factors

including temperature, mix design and stripping time can be closely checked and

controlled; and this will ensure that the quality of the products are better than cast-in­

situ concrete. A huge sum of money will be saved by not having to do rectification

works. Also due to factory-controlled prefabrication environment, many

combinations of colours and textures can be applied easily to the architectural or

structural pieces. A vast range of sizes .and shapes of IBS components can be

produced, providing a great deal of flexibility and offer fresher looks to the

structures.

2.3.5.2 Cleaner and safer construction sites

Usage of IBS components eliminates or greatly reduces conventional

formworks and props. lBS construction also lessens the problem of site wastages and

the related environmental problems. The prefabricated products also provide a safe

working platform for workers to work on. Workers and materials are also greatly

reduced at the construction sites. Using Just-in-Time principles, the IBS components

are kept at the factory yard until the site is ready for installation. Also, as elements

12

are produced in the plant and mostly designed to be repetitive, minimal wastage will

be experienced at both factory and construction sites.

2.3.5.3 Faster construction

lBS construction will save valuable time and helps to reduce the risk of

project delay and possible monetary losses. ms design and production of

components can be started while the construction site is under survey or earthworks.

Production are also unaffected by weather conditions due to the controlled

environment of the casting area. Also, the usage of large precast panels will reduce

the time taken to complete the structural works. Therefore, other trades such as

painting and electrical wiring can begin work sooner.

2.3.5.4 Greater unobstructed span

The usage of prestressed precast solutions such as the Hollow Core slabs and

Double-T beams offer greater unobstructed span than the conventional reinforced

concrete elements. Having lesser beams and columns, will provided larger open

space. It is very ideal for the construction of places of worship, warehouses, halls, car

parks, shops and offices.

2.3.5.5 Lower total construction costs

All of the above simplify the construction processes and increase

productivity, quality and safety. As a result, the total costs of construction are

reduced.