1 RoadMap IBS

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Industrialization ofConstruction Sector


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Industrialised Construction 2

Terms

MMC - Modern MethodConstruction

OFFSITE Pre-casting/fabricating Out of Site

IBS - Industrialised BuildingSystem


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Content

Introduction

Current Scenario of MalaysianConstruction Industry

Promoting IBS SimplifyingConstruction

The Way Forward Case Study

Conclusion


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Endorsed by the

Cabinet 29th Oct2003

Introduction

IBSRoadmap

2003-2010


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. the blueprint document towards

achieving the Industrialization of

the construction sectorand the

longer term objective ofOpen

Building Concept.

IBS ROADMAP 2003 - 2010


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Cabinet

Ministry of Works

[Inter-Ministry coordination committee]

[Chaired by : KSU KKR]

Ministries Agencies

CIDB

Implementation

Coordinator/secretariat

IBS Steering Com.

Stakeholders

Policy

Implementing the Roadmap


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Poor Site Condition

Messy sites

Poor S & H

High wastage

Labour intensive

Low quality

Delays

Current Scenario of Malaysian Construction Industry


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DIRTY

DIFFICULT

DANGEROUS

So what is construction now ?


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Construction techniques in whichcomponents are manufactured in a

factory, on or off site, positioned and

assembled into a structure withminimal additional site works

Promoting Industrialized Building Systems

Simplifying Construction


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positioned and assembled into a structure with

minimal additional site works


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Processing

of steel

Assembly

of floor frame

Assembly of

ceiling frame

Assembly of

sidewall frames

Assembly of

structural unitAttachment of

exterior walls

Application

of insulators

Attachment ofinterior walls

Incorporation of

kitchen facilities

Incorporation of

bath and sanitary

facilities

Final inspection

Packing

ShipmentDeliveryInstallation

Manufactured House (Sekisui)


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FIGURE 4.3 - Knowledge in Industrialised Building

Systems (IBS)

34%

66%

% GOOD % POOR

IBS Survey 2005 Survey on the

Malaysian Architects Knowledge in

IBS Construction


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FIGURE 4.5 - Experience in Using IBS Components in

Building Projects

30%

70%

YES NO

IBS Survey 2005 Survey on the

Malaysian Architects Experience in

Using IBS Components


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CHARACTERISTIC1. Industrial production of components

(prefab, pre-cast under controlledenvironment) or highly mechanised in-situ

processes (slip forms, etc.)

2. Labour reduction3. Modular Coordination - Open building

concept

4. Modern design / manufacturing(ex.CAD/CAM)

5. Systematic Quality Control (ISO 9000

QMS)


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PRE-CAST CONCRETE FRAMING,BOX SYSTEMS


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PRE-CAST CONCRETE FRAMING


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Tunnel forms,

beams andcolumn moulding

forms, permanent

steel formworks

(metal decks), etc

STEEL FORMWORKSSYSTEMS


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Steel beams and

columns, portal frames,

roof trusses, etc

STEEL FRAME SYSTEMS


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Timber frames,roof trusses, etc

PREFAB TIMBERFRAME SYSTEMS


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Interlocking

concrete masonryunit, lightweight

concrete blocks,

etc

BLOCK WORK SYSTEMS


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BENEFITS

1. Reduction of site labour2. Minimal wastage

3. Less site materials

4. Cleaner environment

5. Controlled quality

6. Neater and safer sites7. Faster project completion

8. Lower construction costs

Shorter construction period; if there is consistently large


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Shorter construction period; if there is consistently large

number of apartments to be constructed.Time Scale (Months)

Precast System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Production

Foundation Concurrently done ( with 2 week lead time)

Erection

Finishing

Mechanical & Electrical

Infrastructure

Testing & commisioning

Handing Over

Overall completion Period

Conventional System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Foundation

Construction- superstructure

Finishing

Mechanical & Electrical

Infrastructure

Testing & commisioning

Handing Over

Overall completion Period

18 Month Completion

24 Month Completion


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Labour efficient through

mechanisation, reduces

30% labour


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IBS Not A New Concept

Concept of prefabrication started

from the panellised timberhouses shipped form England to

the new settlements in America

History


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IBS inMalaysia


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IBSComponents


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CIDBs efforts in promotingIBS started since 1998

Earlier, concentrated onAwareness/Promotion/

Training

EARLY EFFORTS


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Usage of IBS in construction of buildings is stillrelatively very low if compared to infra works

(bridges, tunnels, etc)

Only 15% IBS in building

Main Reason :

Relatively cheap and abundant supply of

foreign labourfor Malaysian industry; labourcost in developed economies such as Finland -

10 times the rates in Malaysia

Usage


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Because labour is not going to stay

cheap and abundant forever and

disruption to supply is catastrophic

Industry needs better productivity,

quality and safety to be globally

competitive

Move towards k-economy

Labour is cheap, so why IBS?


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True . components cost higher than

conventional, but in-situ construction has

hidden costs that usually leads to higher

expenditure; due to rectifications, wastages, etc.

Cost higher because:

Low demand

Low standardisation of components (moulds

need to custom made or adjusted to suit

orders)

IBS COMPONENTS AREEXPENSIVE, SO WHY IBS?


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IBS RoadMap 2003-2010

THE WAY FORWARD


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BUILT-IN

COMPONENTS

STRUCTURAL

COMPONENTSRAILING

COMPONENTS

DOOR

COMPONENTS

WINDOW

COMPONENTS

Industrialised ConstructionThrough Components Industry

St d di ti /


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To facilitate open

industrialization,

coordination is

needed in termsof:

Dimensions

Tolerance

Joints and details

Technical

compatibility

Standardisation/Coordination

IBS HOLLISTIC


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Vendors,

manufacturer

Contractor, assemblers, fabricators

Designers,(architects, engineers)

Client/As

set

ma

IBS ComponentCatalogues

Design Guides

IBS - HOLLISTICAPPROACH

Publication Materials
http://images.google.com.my/imgres?imgurl=www.theorangefactory.com/images/factory.gif&imgrefurl=http://www.theorangefactory.com/&h=250&w=247&sz=4&tbnid=SAFvfE9z59YJ:&tbnh=105&tbnw=104&start=17&prev=/images%3Fq%3Dfactory%2B%26hl%3Den%26lr%3D%26ie%3DUTF-8http://images.google.com.my/imgres?imgurl=www.theorangefactory.com/images/factory.gif&imgrefurl=http://www.theorangefactory.com/&h=250&w=247&sz=4&tbnid=SAFvfE9z59YJ:&tbnh=105&tbnw=104&start=17&prev=/images%3Fq%3Dfactory%2B%26hl%3Den%26lr%3D%26ie%3DUTF-8http://images.google.com.my/imgres?imgurl=www.theorangefactory.com/images/factory.gif&imgrefurl=http://www.theorangefactory.com/&h=250&w=247&sz=4&tbnid=SAFvfE9z59YJ:&tbnh=105&tbnw=104&start=17&prev=/images%3Fq%3Dfactory%2B%26hl%3Den%26lr%3D%26ie%3DUTF-8


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MS 1064 : 2001 :GUIDE TO MODULAR

COORDINATION IN BUILDINGS

PART 1: General Principles

PART 2: Storey and Room Heights

PART 3: Coordinating Sizes and Preferred Dimensions for Stairs and Stairs

Opening

PART 4: Coordinating Sizes and Preferred Dimensions for Doorsets

PART 5: Coordinating Sizes and Preferred Dimensions for WindowsetsPART 6: Coordinating Sizes and Preferred Dimensions for Rigid Flat Sheet

PART 7: Coordinating Sizes and Preferred Dimensions for Tiles

PART 8: Coordinating Sizes and Preferred Dimensions for Masonry Bricks and

Blocks

PART 9: Coordinating Sizes and Preferred Dimensions for Cabinets

PART 10: Coordinating Sizes and Preferred Dimensions for RC Components

Gazetted Oct. 2002

Th W F d


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The Way ForwardModular Coordination (MC)

ModularisationBased on MS1064,

MC coordinates thepositions, dimensions of

components and spaces

in building designsBase module :

M = 100 mm


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Strategies

Promote industrialisation;Enforcement; Incentives;

Awareness; Promotion;

Training

Main targethousing sector

Repetitive; High volume


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Closed System

mass - productionone end product

etc.

Mula-mula:Projek

Kemudian:Sistem

Bekalan:Syarikat tertentu

First a project Then a system Always thirdparty supply

Current Scenario


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Open System

DESIGN GUIDE

CATALOGUE

etc.

?

?

First a system Then manyprojects

Open supply

Future Scenario


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IBS Roadmap 2003-2010

1. Manpower

2. Materials/Components/Machines

3. Management/Process/Methods

4. Monetary/Economic/Financial

5. Marketing/Promotion

FIVE main elements


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To have a labour policy that graduallyreduces PERCENTAGE OF FOREIGNWORKERS from the current 75% to 55%

in 2005, 25% in 2007 and 15% in 2009. To incorporate IBS in CPDcourses for

architects, engineers and others.

To incorporate SYLLABUS ON IBS inarchitecture, engineering, buildingcourses in IPTs.

MANPOWER


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Continue efforts to develop NOSS(National Occupational Skill Standards).

Continue Workers training and certification

programme to include all types of IBS. Commence training programme on mould

making for IBS components.

Commence industrial expertise awarenessprogramme together with IBSmanufacturer through on-job training.

MANPOWER


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Commence site supervisory training andcertification programme which includes

knowledge on IBS To start BUMIPUTERA IBS MANUFACTURERS

AND SPECIALISED CONTRACTORS training

and financial aid

MANPOWER


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Enforce use of Modular Coordination

based on MS 1064 through UniformedBuilding By Laws (UBBL) by localauthorities.

Continue publishing reference booksand case study reports regarding IBS.

Continue writing new MalaysianStandards (MS) covering all types of IBS.

Continue writing new Construction

Industry Standards (CIS).

MATERIALS


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Develop software for MC componentsand dimensioning.

Include the IBS/MC knowledge intothe standards of practice and trainingmodules for the training and

certification of Project Manager.

MANAGEMENT


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Offer specialised contractors trainingand certification programmes to

cater for IBS related registrationcodes.

Continually update the website to

disseminate information on IBS, MCand OBS.

MANAGEMENT


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Enforce IBS usage in government(building) projects in phases (from 30%in 2004 to 70% in 2008).

Offerlevy exemptions from 2004 forlow cost, low medium cost andmedium cost housing projects.

Offer training schemes and financialloans for manufacture andcontractors.

MONETARY


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Introduce Buildability Programmebeginning 2006 for private (building)projects and enforcing it through the

local Authorities in 2008. Use IBS construct 30% of the 150,000

units of houses proposed to be built by

Syarikat Perumahan Negara Berhadunder the 2003 Economy StimulusPackages.

MONETARY


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Publish IBS product catalogues. Continue IBS/MC road show

programmes at the national and

international levels.

Establish IBS as the main criteria forMalaysian Construction Industry

Excellence Awards.

Introduce concept of Open buildingSystems to the industry.

MARKETING


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1. Directives- Govt building projects 50% IBS

Score

- 100,000 affordable houses usingIBS

2. Incentive

- Zero levy for residential projects 50% IBS Score

2005 Budget


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IBS Scoring

Part 1 Structural

Element (50%) Part 2 Wall

Element (30%)

Part 3 OtherSimplifiedSolution (20%)


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Case Studies

SJK(C) DAMANSARAPETALING JAYA

SELANGOR DARUL EHSAN

Case Study


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Industrialised Construction 59FEB - MAC 2001

Piling works

Case Study

FEB 2001 Earth works

PROJECT DETAILSCabinets directive - 31Januari 2001

To be completed in 2001 8 monthsproject site : 2 .1 hectarespossession of site : 1 February 2001completion : 31 July 2001

construction period : 5 1/2 months


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MAC 2001

MAC 2001

Fast track project usingprefabricated components

Beams, floor slabs (halfslabs with concrete topping)and staircases wereprefabricated in the factory,wall panel are hollow blocks

Columns and toilets werecast in-situ

Groundlevel

Level 1


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MAC - APRIL 2001

Level 2

APRIL - MEI 2001

Level 3


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APR - MEI 2001

Roof level

External worksJUNE 2001


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Front

elevation

Backelevation

SEK KEB BRICKFIELDS 1 KUALA LUMPUR


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IBS Structure: Hollowcore

slabs; precast concrete columns

& beams

9,900 m2, 4 Floors

Completion in 8 months

SEK. KEB. BRICKFIELDS 1, KUALA LUMPUR


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A compact design fortwo schools in land

area of 48,200 m

2

.

Start of project : 6 February 2003Completion : 17 Sept. 2003

Period : 8 months

i t ll ti f t l


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project constraints limited site, busyaccess, short construction period

75 % of building components wereprefabricated

Prefab components used columns,beams, hollow core floor slabs,staircases, wall panels (Acotechpanels)

installation of precast column


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Architectural features bright faade,cascading roofs with large overhangs,internal pockets of large and smallcourtyards

Installation of first floor slab on 02.05.03

Installation of 3rd floor slab on 28.05.03


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fixing of wall panel


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Completion ofexternal wall on16.07.03

installation of precast staircases

NEW DESIGN FOR


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NEW DESIGN FORGOVERNMENT QUARTERS

In 2001 new design alternativesfor all categories of governmentquarters were initiated

application of modular coordination use of building components flexibility and creativity in design

and the concept of sustainabledesign

standardised components for

interchangeability between designs

Akademi Audit


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Krtrs kelas F & G load bearingdesign, precast wall, slab, column

& beam

Akademi AuditNegara, Nilai

B l i P li

S


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Balai Polis Senawang

Kuaters Kelas FFrame system : cast-in-situcolumn & beam, precast infill

wall & slab

Kuaters Kelas G

IBS PROJECTS


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IBS PROJECTS

HOLLOWCORE SLABS; PRECASTCONCRETE COLUMNS & BEAMS

25,500 m2, 3 FLOORS

STRUCTURAL CONSTRUCTION: 4 MONTHS


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PENANG STATE GOVERNMENT

IBS STRUCTURE: HOLLOWCORESLABS; PRECAST CONCRETE

COLUMNS & BEAMS

7,500 m2, 4 FLOORS

STRUCTURAL CONSTRUCTION: 2

MONTHS

DEWAN MILENIUM, KEPALA BATAS

INDOOR STADIUM, BALIK PULAU


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MAJLIS PERBANDARAN PPINANG

IBS STRUCTURE:HOLLOWCORE SLABS;

PRECAST CONCRETE

COLUMNS, BEAMS &

BLEACHERS

6,000 m2, 3 FLOORS

STRUCTURAL

CONSTRUCTION: 2 MONTHS

,

RESIDENTIAL & OFFICE


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IBS STRUCTURE: METAL

FORMWORKS FOR WALLS,

SLABS, BEAMS & COLUMNS

TWO 26-30 STOREY TOWERS(APARTMENTS & OFFICES)

STRUCTURAL


NORTHAM CITY, PULAU PINANG

IBS STRUCTURE: TEACHERS QUARTERS,


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IBS STRUCTURE:

LIGHTWEIGHT BLOCKS &

PRECAST CONCRETE WALLS;

PRECAST CONCRETE SLABS

10,000 UNITS, 4-5 STOREY

109 LOCATIONS IN 9 STATES

COMPLETION IN 3 YEARS

TEACHERS QUARTERS,

ALL OVER MALAYSIA

AKADEMI BINAAN MALAYSIA,


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CIDB MALAYSIA

IBS STRUCTURE: PRECAST

CONCRETE SLABS, BEAMS,

COLUMNS & WALLS 9,600 m2, 6 WORKSHOP

BLOCKS

STRUCTURAL


SINTOK, KEDAH

HOSPITAL SERDANG SELANGOR


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MINISTRY OF HEALTH

620-BED HOSPITAL

HYBRID IBS STRUCTURE OF

STEEL FRAMES; PRECAST

CONCRETE SLABS;

LIGHTWEIGHT CONCRETE

BLOCKS FOR WALLS

130,000 m2, 9 FLOORS

STRUCTURAL CONSTRUCTION:

4 MONTHS

HOSPITAL SERDANG, SELANGOR

SHOPPING COMPLEX DAMANSARA


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IBS STRUCTURE: SOLID & HOLLOWCORE

SLABS; PRECAST CONCRETE WALLS,

STAIRCASES, GUTTERS, BEAMS & COLUMNS 121,000 m2, 4 FLOORS, 2 BASEMENTS

STRUCTURAL CONSTRUCTION: 4 MONTHS

SHOPPING COMPLEX, DAMANSARA

RESIDENTIAL APARTMENTS,

PUTRAJAYA


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IBS STRUCTURE: PRECAST

CONCRETE SLABS, WALLS &

STAIRCASES

756 UNITS, 6 BLOCKS, 8-16FLOORS


PUTRAJAYA

Concl sion


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Conclusion

IBS ROADMAP 2003-2010: Towardslabour reduction and better

productivity, quality, safety &

environment; reducing total industrycosts

INCREASING THE CONSTRUCTION

INDUSTRY COMPETITIVENESS


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Industrialised Construction83

Thank You


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