Ibs Complete

RMT 558_Construction Management & Facilities Management 2009

Industrialised Building System(IBS) by Jaspal Azam,Hidayah,Sharon,Syafiq,Ooi 1

CHAPTER 1.0 - INTRODUCTION

The industrialized building system (IBS) can be generally interpreted as in which

all building components such as floors, walls, columns, beams, and roofs are

mass produced either in a factory or at site factory according to specifications

with standardize shapes and dimensions and transported to the construction

projects site to be assembled into a structure with minimal site wet work and

erected on the site properly joined to form the final units.

The development of industrialized building system (IBS) is not new in the

construction industry. The history of IBS in the UK housing industry dates back

from the mid 1900’s, when this and other forms of prefabricated construction

were used to address the problem of widespread destruction of housing stock

during the Second World War.

In the United States, the use of precast building components in the construction

industry began in the construction of prefabricated steel house by General House

in 1930. However the early efforts of rationalizing and implementation faded

quickly due to price in competitiveness, high capital and inconsistent local codes.

The use of precast building components increased sharply after the Second

World War due to the need to resolve critical shortage of houses.

The idea of industrialised building system (IBS) has received much attention in

the devastated countries after the Second World War. Though, Malaysia did not

suffer the impact of the war, the need to supply its population with affordable and

quality houses has prompted the government to promote the use of IBS as an

alternative to conventional building system.



The implementation of precast concept by using precast concrete building were

introduced in Malaysia in 1966 when the government launched two pilot projects

for precast housing which involves the construction of Tuanku Abdul Rahman

Flats in Kuala Lumpur and the Rifle Range Road Flats in Penang. Both projects

were the first time whereby precast elements were used to construct mass

houses. Later, Perbadanan Kemajuan Negeri Johor (PKNS) import the precast

concrete technology from Germany for the construction ranging from low cost

housing to luxurious housing such as bungalows and semi detached.

1.1 Definition of IBS

To date there has been no one commonly-accepted or agreed definition of IBS.

However, there are a few definitions by researchers and experts in this field

which can be found through literature. Rahman and Omar (2006) defined IBS as

a construction system that is built using pre-fabricated components. The

manufacturing of the components is systematically done using machine,

formworks and other forms of mechanical equipment.

IBS is defined as products, systems and techniques used in making construction

less labour-oriented, faster as well as quality controlled. It generally involves

prefabricated products, factory manufactured elements that transported to the

construction sites and erected. (Shaari, Bulletin Ingénieur, 2003)

According to Abraham Warszawski (1999), IBS is defined as a set of element or

component which is inter-related towards helping the implementation of

construction works activities. He also expounded that an industrialisation process

is an investment in equipment, facilities, and technology with the objective of

maximising production output, minimising labour resource, and improving quality

while a building system is defined as a set of interconnected element that joint

together to enable the designated performance of a building.



Trikha (1999) defined IBS as a system in which concrete components

prefabricated at site or in factory are assembly to form the structure with

minimum in situ construction.

Esa and Nuruddin (1998) asserted that IBS is a continuum beginning from

utilising craftsmen for every aspect of construction to a system that make use of

manufacturing production in order to minimise resource wastage and enhance

value for end users.

Perhaps the most comprehensive definition of IBS was clarified by Junid (1986).

He mentioned that IBS in the construction industry includes the industrialised

process by which components of a building are conceived, planned, fabricated,

transported and erected on site. The system includes a balanced combination

between the software and hardware components.

The software elements include system design, which is a complex process of

studying the requirement of the end user, market analysis, development of

standardised components, establishment of manufacturing and assembly layout

and process, allocation of resources and materials and definition of a building

designer conceptual framework. The software elements provide a prerequisite to

create the conducive environment for industrialised to expand.

Meanwhile, the hardware elements are categorised into three major groups.

These include frame or post and beam system, panel system, and box system.

The framed structures are defined as those structures that carry the loads

through their beams and girders to columns and to the ground whilst in panel

system load are distributed through large floor and wall panels. The box systems

include those systems that employ three-dimensional modules (or boxes) for

fabrication of habitable units are capable of withstand load from various

directions due to their internal stability.



All the above definitions emphasised on prefabrication, off-site production and

mass production of building components as the main characteristic of IBS. The

focal of discussion in the study synergises the key concept of IBS as defined as

follows: A construction technique in which components are manufactured in a

controlled environment (on or off site), transported, positioned and assembled

into a structure with minimal additional site works (CIDB, 2003a).

1.2 Classification of IBS

Warszawski (1999) asserted that the building system could be classified in

different ways, depending on the particular interest of their users or producers.

Such classification use construction technology as a basis for classifying different

building systems. In this manner four major groups can be distinguished namely,

system with (1) timber, (2) steel, (3) cast in situ concrete, and (4) precast

concrete as their main structural and space enclosing materials. These systems

can be further classified according to the geometrical configuration of their main

framing components as follows (1) linear or skeleton (beams and columns)

system, (2) planar or panel systems, and (3) three dimensional or box systems.

According to Badir- Razali, generally, there are four types of building systems

currently available in Malaysia’s building system classification (Badir et al. 1998),

namely conventional, cast in-situ, prefabricated and composite building systems.

Each building system is represented by its respective construction method which

is further characterised by its construction technology, functional and geometrical

configuration.



Fig. 1.1 Type of building system in Malaysia

Nonetheless, according to CIDB (2003), the structural aspects of IBS of the

systems, divided into five major types as follows:

1. Precast Concrete Framing, Panel and Box Systems

Precast columns, beams, slabs, 3-D components (balconies,

staircases, toilets, lift chambers), permanent concrete formwork, etc;

Figure 1.2 Precast concrete wall



2. Steel Formwork Systems

Tunnel forms, beams and columns molding forms, permanent steel

formworks (metal decks, etc;

Figure 1.3 Steel formwork system

3. Steel Framing Systems

Steel beams and columns, portal frames, roof trusses, etc;

Figure 1.4 Steel roof trusses



4. Prefabricated Timber Framing Systems

Timber frames, roof trusses, etc;

Figure 1.5 Prefabricated timber framing system for a double storey

house.

5. Block Work Systems

Interlocking concrete masonry units (CMU), lightweight concrete

blocks, etc.

Figure 1.6 Lightweight concrete blocks are used for wall construction



The pre-cast concrete components are among the most common prefabricated

elements that are available both locally and abroad. The pre-cast concrete

elements are concrete products that are manufactured and cured in a plant

environment and then transported to a job site for installation. The elements are

columns, beams, slabs, walls, 3-D elements (balconies, staircase, toilets, and lift

chambers), permanent concrete formwork and etc.

The steel formwork is prefabricated in the factory and then installed on site.

However the steel reinforcement and services conduit are installed on site before

the steel formwork are installed. The installation of this formwork is easy by using

simple bracing system. Then concrete is poured into the formwork and after

seven days, the formwork can be removed and there is some system whereby

the formwork served as a part of the structure itself after concreting. The steel

formwork systems are used in tunnel forms, beams, column moulding forms and

permanent steel formworks.

The elements of steel framing system are rolled into the specific sizes and then

the elements are fabricated that involves cutting, drilling, shot blasting, welding

and painting. Fabricated elements are sent to the construction site to be then

erected whereby welding and the tightening of bolts at joints are conducted. The

elements include steel beams and columns, portal frames and roof trusses.

The prefabricated timber framing system is normally used in the conventional

roof truss and timber frames. The timber is prefabricated by joining the members

of the truss by using steel plate. It is important that all members are treated with

the anti pest chemical. Then, the installation is done on site by connecting the

prefabricated roof truss to the reinforcement of the roof beams.

The elements of block work system include interlocking concrete masonry units

(CMU) and lightweight concrete blocks.



The elements are fabricated and cured in the factory. The elements are normally

used as bricks in structures and interlocking concrete block pavement.

1.3 Essential Characteristics of IBS

It is plausible to review the prerequisite characteristics underlining the successful

implementation of industrialised building system. Each of them is briefly

discussed below.

1.3.1 Closed System

A closed system can be classified into two categories, namely production

based on client’s design and production based on precaster’s design. The

first category is designed to meet a spatial requirement of the client’s that

is the spaces required for various functions in the building as well as the

specific architectural design.

In this instance, the client’s needs are paramount and the precaster is

always forced to produce a specific component for a building. On the other

hand, the production based on precaster’s design includes designing and

producing a uniform type of building or a group of building variants, which

can be produced with a common assortments of component. Such

building includes school, parking garage, gas station, low cost housing,

etc. Nevertheless these types of building arrangement can be justified

economically only when the following circumstances are observed

(Warszawski, 1999).

(a) The size of project is large enough to allow for distribution of

design and production costs over the extra cost per component

incur due to the specific design.



b) The architectural design observes large repetitive element and

standardisation. In respect to this, a novel prefabrication system

can overcome the requirement of many standardised elements by

automating the design and production process.

c) There is a sufficient demand for a typical type of building such as

school so that a mass production can be obtained.

d) There is an intensive marketing strategy by precaster to

enlighten the clients and designer the potential benefit of the

system in term of economics and non-economic aspects.

1.3.2 Open System

In view of the limitations inherent in the closed system, an open system

which allows greater flexibility of design and maximum coordination

between the designer and precaster has been proposed. This system is

plausible because it allow the precaster to produce a limited number of

elements with a predetermined range of product and at the same time

maintaining architectural aesthetic value.

In spite of many advantages inherent in an open system, its adoption

experiences one major setback. For example, joint and connection

problem occur when two elements from different system are fixed

together. This is because similar connection technology must be observed

in order to achieve greater structural performance.



1.3.3 Modular Coordination

Modular co-ordination is a co-ordinated unified system for dimensioning

spaces, components, fitting, etc. so that all elements fit together without

cutting or extending even when the components and fittings are

manufactured by different suppliers (Trikha, 1999).

The objectives of modular co-ordination are:

a) To create a basis upon which the variety of types and sizes of

building components can be minimized. Through a rationalized

method of construction, each component is designed to be

interchangeable with other similar ones and hence, provide a

maximum degree of freedom and choice offered to the designer.

This can also be accomplished by adopting a relatively large basic

measurement unit (basic module) and by limiting the dimensions of

building components to recommended preferred sizes

(Warszawski, 1999).

b) To allow for easy adoption of prefabricated components to any

layout and for their interchange ability within the building. This is

achieved by defining the location of each component in the building

with reference to a common modular grid rather than with a

reference to other components (Warszawski, 1999).

The modular co-ordination for building component apply the basic length

unit or module of M=100cm. This allows the designer to apply this size or

its multiple in the production of building components.



Although this concept seems to be easy for adoption, its application

involves a great degree of coordination and adjustment in the

manufacturing process and the interfacing aspects of components.

1.3.4 Standardisation and Tolerances

For accomplishing the requirement of modular co-ordination, all

components need to be standardised for production. Such standardisation

of space and elements need prescribing tolerances at different

construction stages such as manufactured tolerances, setting out

tolerances, and erection tolerances, so that the combined tolerance

obtained on statistical considerations is within the permitted limits (Trikha,

1999).

Production resources can be used in the most efficient manner if the

output is standardised. Then the production process, machinery, and

workers’ training can be best absorbed to the particular characteristics of

the product.

1.3.5 Mass Production

The investment in equipment, human recourses, and facilities associated

with an industrialisation can be justified economically only when large

production volume is observed. Such volume provides a distribution of the

fixed investment charge over a large number of product units without

unduly inflating their ultimate cost (CIDB Singapore, 1992).



1.3.6 Specialisation

Large production output and standardisation of precast elements allow a

high degree of labour specialisation with the production process. The

process can be subdivided into a large number of small homogenous

tasks. In such working condition, workers are exposed to their work

repetitiously with higher productivity level (Warszawski, 1999).

1.3.7 Good Organisation

High production volume, specialisation of work, and centralisation of

production requires a efficient and experiences organisation capable of a

high level of planning, organising, coordination and control function with

respect to production and distribution of the products (Warszawski, 1999).

1.3.8 Integration

In order to obtain an optimal result, a high degree of coordination must

exist between various relevant parties such as designer, manufacturer,

owner, and contractor. This is achieved through an integrated system in

which all these functions are performed under a unified authority

(Warszawski, 1999)

1.3.9 Production Facility

The initial capital investment for setting up a permanent factor is relatively

experience. Plant, equipment, skilled worker, management resources

need to be acquired before production can be commenced. Such huge

investment can only be breakeven if there is sufficiently demand for the

products.



On the other hand, a temporary casting yard or factory can be established

at the project site in order to minimise the transportation costs (Peng,

1986).

1.3.10 Transportation

It is found that casting of large-panel system can reduce labour cost up to

30 percent. However, these cost savings are partially offset by the

transportation costs. The transportation of large panels is also subject to

the country’s road department requirement. These limitations must be

taken into consideration when adopting a prefabrication system

(Peng, 1986).

1.3.11 Equipment at Site

For the purpose of erecting and assembling precast panels into their

position, heavy crane is required especially for multi-storey building. It is

therefore important to incorporate this additional cost when adopting a

prefabrication system (Warszawski, 1999).



CHAPTER 2.0 - DEVELOPMENT OF IBS IN MALAYSIA

IBS in Malaysia has begun in early 1960’s when Ministry of Housing and Local

Government of Malaysia visited several European countries and evaluate their

housing development program (Thanoon et. al., 2003). After their successful visit

in 1964, the government had started first project on IBS aims to speed up the

delivery time and built affordable and quality houses. About 22.7 acres of land

along Jalan Pekeliling, Kuala Lumpur was dedicated to the project comprising

seven blocks of 17 storey flat there are 3000 units of low-cost flat and 40 shops

lot. This project was awarded to Gammon/ Larsen Nielsen using Danish System

of large panel of pre-fabricated system (CIDB, 2003b).

In 1965, the second housing project initiated by the government of Malaysia, the

project comprising a 6 block of 17 storey flat and 3 blocks of 18 storey flat at

Jalan Rifle Range, Penang. The project was awarded to Hochtief/Chee Seng

using French Estoit System (Din, 1984). Among the earliest housing

development project using IBS was Taman Tun Sardon, Penang. IBS pre-cast

component and system in the project was designed by British Research

Establishment for low cost housing in tropical countries. Nonetheless, the

building design was very basic and not considering the aspect of serviceability

such as the need of wet toilet and bathroom (Rahman and Omar, 2006).

Between 1981 and 1993, Perbadanan Kemajuan Negeri Selangor (PKNS) a

state government development agency acquired pre-cast concrete technology

from Praton Haus International based on Germany to build low cost house and

high cost bungalow in Selangor (CIDB, 2003b). The usage of steel structure as

part of IBS, first gained attention with the construction of 36-storeys Dayabumi

complex that was completed in 1984 by Takenaka Corporation of Japan (CIDB,

2003b).



Today, the use of IBS as a method of construction in Malaysia is evolving. Many

private companies in Malaysia have teamed up with foreign expert from

Australia, Netherlands, United State and Japan to offer pre-cast solution to their

project (CIDB, 2003b). In addition, more and more local manufacturers have

established themselves in the market. Pre-cast, steel frame and other IBS were

used as hybrid construction to build national landmark such as Bukit Jalil Sport

Complex, Lightweight Railway Train (LRT) and Petronas Twin Tower. It was

reported that at least 21 of various manufactures and suppliers of IBS are

actively promoting their system in Malaysia (Thanoon et al., 2003). Nevertheless,

the government of Malaysia still feels that the usage of IBS is still low despite the

plausible potential.

From the survey conducted by CIDB of Malaysia in 2003, the usage level of IBS

in local construction industry stands at 15% (CIDB, 2003b). The total registered

IBS contractors in Malaysia stand for 1,993 in year 2007 (Table 3 and 4) and

registered IBS manufacture in Malaysia until 2007 is 138 producing 347 IBS

products available in the market shown in Table 5.

Evidently that most of locally developed products are based on traditional

materials such as reinforced concrete and the most innovative materials are

based on imported technology (CIDB, 2007b). There is no mandatory

requirement on any certification or accreditation of components, companies or

installers in place. Whilst, there is no empirical data, there is some anecdotal

evidence suggests that there has been sporadic dumping of sub-standard foreign

products in Malaysia (CIDB, 2007b). A mechanism to ensure IBS products

marked to an acceptable standard must be introduced in the manufacturing

process. Testing of components, verify and certify them will limit only safe and

acceptable IBS panels are erected and thus CIDB will lead this roles.



2.1 Implementation of IBS in Malaysia

In Malaysia, the implementation of IBS concept by using pre-cast concrete

building were introduce in Malaysia 1966 when the government launched two

pilot projects for pre-cast housing which involves the construction of Tuanku

Abdul Rahman Flats in Kuala Lumpur and the Rifle Range Road Flats in Penang.

Both projects were the first time whereby pre-cast elements were used to

construct mass houses.

Since 1980’s there are intensive marketing strategies launched by the Malaysian

Government t o introduce modular coordination, its acceptance has received

poor responses for the building industry. As a result even partial introduction on

IBS such as lintels and staircase has not been possible (Trikha, 1999).

Previously in the 7th Malaysia Plan, the country intended to construct about

800,000 units of houses for its population using the IBS construction, Indeed

585,00 units planned for the low and low medium cost houses. However the

achievements are disappointing with only 20% completed houses reported due to

use of conventional construction method. Although the government introduce

numerous incentives and promotions to encourage housing developer’s t invest

in such housing category (Ismail, 2001).

Under the 7th Malaysian Plan, the enforcement of modular Coordination through

the construction Industry Standard 1 & 2 only applies to the low cost housing

projects initiated by the ministry of Housing and Local Government Malaysia

(CIDB 2001). The enforcement by the local authorities did not apply to all the

parties involve in the construction contribute to the failure or the implementation

in Malaysia. Furthermore the incentives that promised to be given to developers

by the government does not clearly stated in the law of Malaysia.



This is non conformance leads to the use conventional method which is less risky

to the developers.

In the 1998, the ministry of housing and local government and CIDB has come

up with the modular design guide which contain the modular coordination

concepts, the design rules, drawings and preferred dimensions for architectural

finishes material such as bricks, glass, gypsum board and etc. the important

aspects of prefabricated concrete in terms of modular dimensions, strength,

stability and the fire protection specifications are not indicated. The uniform

building by law (UBBL) has introduced several clauses to encourage the use of

IBS include the sub clause of 42(1):

a) The second line mentioned that ’11 meter square gross area’ is

replace by the ’10.8 meter square net area’ this is suitable for the area

room that has the dimension of 3000x3600mm and using the modular

dimension.

b) The forth line, ‘9.3 square gross area’ is replace by the ‘9.0 meter

square net area.’

c) The fifth line, ‘6.5 meter square gross area’ is replace by’6.3 meter

square net area

In the conventional construction the local authority only given the authority to

inspect the work after the completion of the project which is not practical. The

government should look into allowing the local authority to inspect the work in the

manufacturing process up the construction stage and lastly to the project

completion to ensure the quality is not compromised.



In the year 2001, the government set the Malaysia standard 1064 in order to

standardize the IBS components in terms of dimensions. However the MS 1064

still have a lot of loop holes that still can be improve.

The important specifications such as types of materials, design standard,

connection types, construction method and the system implementation are not

included. These items will ensure the quality of IBS components can be improve

and the contractor can be implement a standardize system easily and this will

encourage the use of IBS in Malaysia especially in the private sector. However

the standards must not be too rigid to allow for technological improvement in

constructions method, system and etc.

Many involvements in materials and components are made before their

application in the building process. In most cases, construction firm acts as

system integrators and catalyst for transforming new technologies into

marketable products. These play an important role modifying and developing

new technologies that impact as feedback loop to producers in the upstream.

The forces for technology for adoption are the strongest among materials,

component manufacturers and high quality equipment for production purposes.

Property developers and government policy makers also feed the stream for

innovation by funding in research and development activities.

2.2 Impediments to progress of IBS in Malaysia

The government is the major key player in the construction industry has spent

billions of ringgit over the pat several Malaysia Plans to develop the country.

However the plans are the characterized by short falls, delays and lack of

coordination between all parties including the agencies at federal and state levels

and other major players in the constructions industry. The government has not

taken necessary actions for the globalization and the industrialization of the



construction industry. The selection of the IBS has been hindered by lack of

assessment criteria set by the approving authorities.

An IBS system can only be practiced by the practitioner if its major advantages

are valuable compare to the conventional system. However up to date, there is

inadequate collaborative scientific research undertaken to substantiate the

benefit of IBS system. Therefore it can be clearly seen that the implementation of

IBS is hindered by lack of scientific information. The academic curriculum in the

university seldom in corporate courses that technology, organization and the

construction and the design of IBS. Lack of the research and development to use

the local materials causes the dependence of foreign technology can be

expensive and quality of products may be compromised

The fragmented construction industry straddles over several professions and

business. The professionals, builders and the supplier do not communication to

input on ideas on implementation of IBS. However the main concerns for these

parties are just profit and the resistance to change due to unclear incentives

given by the government by using new technology.

The research output from research institution is not readily commercially

exploitable and does not appeal to potential users. The major players of the

construction industry are reluctant to carry out the research and development in

IBS because this can be seen as risky ventures. The country has not been

embarked upon venture capitalism in a proactive meaningful manner and as

such effort in universities and research institutions remain largely unexploited

and unused.

All parties involve in the construction industry should collaborate and to work

together in order to achieve the full utilization of IBS.



The government play very important role in imposed new regulation, standard

and training in terms of knowledge, experience and construction method.

Moreover the standardization of dimensions of material needs to provide a

feedback loop from the constructor to enable the implementation to be improving

from time to time.

Incentives given by government should be clearly documented and making sure

that all parties is well informed through promotions by the media. Last but not

least, the government should have the authority over parties involved including

manufacturer, constructor, designer, financial institution and the transporters to

ensure they play heir respective roles in the successful implementations of IBS



CHAPTER 3.0 - ISSUES AND CHALLENGES IN IBS IMPLEMEN TATION IN

MALAYSIA

3.1 Introduction

CIDB has published IBS Roadmap 2003- 2010 which entailed the needs and

requirement of Malaysian construction industry. This roadmap was endorsed by

Cabinet on 29th October 2003. The roadmap is a comprehensive document that

divides the IBS programmed into five main focus areas that reflect the inputs

needed to drive the programmed. They are Manpower, Materials, Management,

Monetary, and Marketing (CIDB, 2003a).

The inputs are then divided into elements and the activities to be implemented for

each element are then identified and included into the time span of the roadmap

in order to achieve the mission within the stipulated time-frame. The content of

this roadmap is focused towards achieving the industrialization of the

construction sector and the longer term objective of Open Building concept. It

has been five years since the launching of the roadmap and more than half-way

through the mission of industrializing construction (Hussein, 2007).

It is now pertinent to examine the progress and how close to the completion of

the mission to date. More importantly, it is imperative to evaluate whether the

implementation of the roadmap has met the market response to the IBS

programmed so far. Most policy issues have been resolved and implemented,

while all relevant documents required to support the programmed have been

developed. Notwithstanding these achievements a number of implementation

snags were identified as being potential hurdles to the full implementation of the

roadmap.



These include the following which have been identified by IBS Steering

Committee 2003- 2005 (Hussein, 2007):

• Development of standard plans and standard component drawings

for common use,

• Apprentice and on-the-job training in the area of IBS moulds and

casts, and assembly of components,

• IBS testing and evaluation programmed,

• Vendor development program,

• Readiness of designers and consultant practices, quality control,

production of standard components in the field of IBS.

`Realizing the implementation of IBS is still to make headway, CIDB through its

research arm, Construction Research Institute of Malaysia (CREAM) has taken

the initiative from the problem identified earlier and has conducted three

workshops session with the industry between 2006 and 2007.



3.2 Challenges & Issues on IBS

After a lengthy deliberation with the stakeholders, it was concluded that the

factors contributing to the delays of IBS implementation are as follows:-

3.2.1 IBS as mass construction method.

The term ‘IBS’ is often misinterpreted with negative meaning as it is

always linked with industrialized buildings that were built in1960s. These

buildings are normally associated with pre-fabricated mass construction

method, low quality buildings, leakages, abandoned projects, unpleasant

architectural appearances and other drawbacks. Due to the poor

architectural design, the old pre-fabricated buildings have given the public,

bad impression about precast concrete.

There have been quite a number of cases where the use of IBS had lead

to such drawbacks. For example, in the case of Pekeliling Flats in Kuala

Lumpur and Taman Tun Sardon, Gelugor, Penang. These two early pre-

fabricated flats were constructed in mass to produce low cost

accommodation for lower income groups. In the case of Taman Tun

Sardon, the IBS precast system was designed by British Research

Establishment, UK for low cost housing in tropical countries.

However, the design was very basic and not considering the aspect of

serviceability such as the need for wet toilets and bathrooms. Lacking in

this design consideration leads to problems of leakage that becomes the

common issue with precast buildings. In addition, in many cases the low

cost housings are not maintained properly, thus contributing further to the

poor image of IBS buildings.



3.2.2 Lack of involvement from small contractors

From the survey it is found that many small contractors are reluctant to

adopt IBS system and prefer to continue using the conventional method of

construction. This is due to the fact that small contractors are already

familiar with the conventional system and for them the technology suit well

with small scale projects and therefore not willing to switch to mechanized

based system. Furthermore small contractors lack financial backup and

are not able to set up their own manufacturing plants as it involves very

intensive capital investment. In this case, financial issues become the

main obstacle for small contractors to move forward with the IBS system.

On the other hand, however, many big players in IBS industry have shown

good track records in building successful IBS projects. This shows that

IBS is a feasible system provided the parties involved have the capabilities

to carry out the work related to IBS such as analysis, design and

manufacturing of IBS components.

3.2.3 Lack of knowledge and exposure to IBS technology

Lack of knowledge in structural analysis and design of pre-fabricated

components among civil engineers and those related to construction

discourages further the implementation of IBS system. Unlike steel

structures, the subject of precast concrete design is normally not delivered

to undergraduate students in many universities. As a result, many junior

engineers are not really familiar with the precast concrete technology as

compared to structural steelwork. Knowledge in construction technology is

equally important. There are cases, where building projects are awarded

and constructed using IBS system but were carried out with many

difficulties.



The most common problems encountered are improper assembly of the

components that normally involved the beam-to-column and column-to-

base connections. These problems arise due to the fact that the parties

involved in the construction underestimate the important of accuracy in

setting out the alignment and levelling of the bases. Basically, accurate

levelling and alignment of the bases are the two most important aspects

for the successful rapid erection of precast concrete components. Other

related technical issues are lack of knowledge capability in designing the

details of ties and connections of the pre-fabricated components

particularly in precast concrete construction. Poor connection system may

cause problem to site work such that the connections cannot be joined

properly due to poor construction details. In the case of steelwork

structures, there are many cases where buildings were designed to imitate

the conventional reinforced concrete structural system. This concept

results in exposed steel beams and columns. Eventually this invites many

serviceability problems such as leakage. Rain water can easily seep into

the internal building through the joint between the wall and steel beam.

Dampness leads to corrosion to the lighting system and the steel beam.

3.2.4 Designing a Feasible IBS System

IBS system if properly designed can deliver a more efficient construction

process due to many advantages such as greater speed of construction,

simpler construction process, reduced environmental impact and reduce

reliance on traditional labours. Therefore the challenge is to provide a

feasible and innovative IBS system that is acceptable to those involved

with construction as well as the users.

In order to achieve a feasible IBS system, the aspect of standardization

should be incorporated in designing the system.



The standardisation can include the use of standard connections,

standard beam and column sizes. Standardisation of components may be

incorporated to reduce the cost of manufacturing. By implementing

standardization, many errors in production or erection due to variability

can be reduced. Standardisation may lead to improvement in quality,

decrease variability and increase the ease of manufacturing. In this case,

the challenging aspect related to a feasible system is the manufacturing of

the components.

For example, the steel mould used to form beams and columns must have

high degree of precision to produce accurate and consistent dimensions of

width, breadth and length and other related dimensions. The mould should

be of high quality with enough durability and strength and not easily

becomes dented or buckled during compaction of the concrete. In the

case of mechanical connections, the built in connection accessories to be

cast in the concrete component, must be located precisely prior to

concreting. Similarly any sleeves or opening in the component must be

done accurately.

3.2.5 Investment on Heavy Equipment for Mechanized Constr uction

System

The successful IBS construction system has some degree of dependency

to heavy and special equipment such as cranes. The high initial cost in

setting up the manufacturing plant as well as the cost of transportation has

reduced the margin of profit. It has been noticed that despite all the

advantages of adopting IBS, a significant portion of the construction

industry players still has a biased perception on IBS system. It is admitted

presently that switching to IBS would not guarantee significant savings in

the cost especially with the small volume of buildings constructed.



However, IBS has demonstrated that the savings in the construction time

is able to compensate the higher construction cost incurred.

3.2.6 Awareness

In order for IBS system to be understood and used widely, the challenge is

to create mechanism of awareness. Many contractors and even engineers

are not well aware of the IBS system and not involved with the use of any

IBS system in their construction methods. Therefore, in order to create

awareness among practicing engineers and contractors, campaign to

reassure that IBS systems are able to provide fast, economical and high

quality products should be carried out.

The awareness campaigns may include seminars and short courses. For

example, CIDB in collaboration with universities, manufacturers and

professional bodies have carried out extensive seminars and roadshow to

give exposure to contractors and engineers about the IBS system. Also,

hands-on trainings in specialised works such as operating cranes and

welding works are also conducted to provide specilised and trained

workers in the IBS industry.

3.2.7 Knowledge

Specialized and additional engineering knowledge will be required to

design, manufacture and construct a good IBS system. All parties involved

from designers to erectors must have enough knowledge about the pre-

fabricated component based construction. In terms of design, the

engineers must have competent knowledge in analysis and design. In the

construction field, the contractors and site engineers must have enough

knowledge on the safe and accurate methods of erecting and assembling

loose components into a global structure.



At university level, the students should be taught structural design

principles, material technologies and construction practices related to IBS

system such as precast concrete structures. Some local universities are

currently improving their curriculum by adding new topics related to IBS in

the existing syllabus. For example subjects related to precast concrete

design and construction are also offered as elective for final

undergraduate and graduate students. Apart from that, testing and

research have to be conducted to prove feasibility of design. Knowledge

gained from advanced research may elevate the level of understanding on

the behaviour of IBS structure and consequently the level of confidence.

Engineers with good technical knowledge in analysis, design,

manufacturing and construction have the ability to produce systematic IBS

systems. If the components are skillfully designed, erection can be carried

out efficiently. Furthermore, complying with good practices in design and

construction leads to high quality precast concrete structures. In this

aspect, the challenge is to produce many good and reliable manufacturers

and erectors with such knowledge capabilities to be part of the IBS

construction team.

3.2.8 Adoption of IBS System

The government through CIDB has embarked the IBS Roadmap 2003-

2010 that outlines several well-thought strategies and aggressive steps to

promote the use of IBS in Malaysia To facilitate further, the government

has encouraged the use of IBS for the construction of new government

quarters. Contractors adopting the IBS system are given incentive such as

levy exemption based on the percentage of IBS usage in a project.. The

government is taking the leading role in persuading the construction

industry to adopt a more systematic approach and methodology in

construction.



The effort, started in 1998, is a strategic change in the construction

industry. If IBS is adopted, efficient, clean, safe and innovative are some

of the new attributes that will be associated with the construction industry.

With these outstanding features, plus attributes such as professionally

managed and handled, workers with relevant skills, proper coordination

and management as well quality will inevitably make IBS an excellent

option for those involved in the industry to become global industry players

in the international arena that demands high quality, efficient and

professional services.

3.2.9 - Barriers to IBS Implementation

Despite the plausible advantages, the majority of contractors are sceptical

to use IBS method. In fact, the majority of contactors are not ready to bid

IBS construction tender. Warszawski (1999) highlighted implementation

risk of using IBS compared to conventional labour intensive method and

later observed that adaptation of standardization requires a tremendous

education and training effort. Pan et al. (2008) has highlighted the barriers

of using IBS construction in a survey conducted for UK housebuilders. The

most mention barriers according to UK housebuilders are higher in capital

cost, complex interfacing between systems and the nature of UK planning

system which is not favourable to IBS. Goodier & Gibb (2006) highlighted

barriers hindering the use of IBS that include an increase in overall cost,

client resistance, lack of guidance and information, increased in risk and

insufficient workers skill. In a report on off-site manufacturing in Australia,

Blismas (2007) observed that very low IT integration in the construction

industry, high fragmentation in the industry, cost related issues, a lack of

codes and standards, difficulties in financing, limited capacity of suppliers

as the barriers contribute to limited take up on IBS. It also observed that

transportation of panels and modules is much more difficult in IBS

construction (Rahman & Omar, 2006).



More serious is the problem of making joints, locking, gluing, welding,

hammering or snapping components together which need time and

experience for perfection and reduced wastage. Moreover, the method

itself involving mechanized system and skilled worker to coordinate and

assembly introduces demand of precision not needed in other method.

IBS also appear to be slightly an expensive choice over the traditional

method and not appealing option which need extensive training and

apprenticeship (Thanoon et al. 2003) (Rahman & Omar, 2006).

3.2.10 Negative perception on IBS

Rahman & Omar (2006) observed that the term IBS is often misinterpreted

with negative image due to its past failures and unattractive architecture.

These buildings are normally associated with pre-fabricated, mass

construction method, low quality buildings, leakages, abandoned projects,

unpleasant architectural appearances and other drawbacks. Due to the

poor architectural design, the old pre-fabricated buildings have given the

public, bad impression about pre-cast concrete. Clients are often in doubt

of using IBS because of fear of customer rejection. Even construction

professionals are in doubt in IBS technology and relate IBS with a

potential post-construction problem. In addition, it is always not popular

among the designers as they found pre-fabrication has limiting their

creativity in design process (Hamid et al. 2008).

It is observed that lack of IBS branding and promotion taking place in the

market as the end user are neither misinterpret nor unaware of this

construction method. As a result, IBS is not creating enough pull factors to

encourage developers to adopt IBS. In comparison, IBS development in

Scandinavian and Japan provide higher customer focus and adopt mass-

customization of to enrich customer option. In UK, IBS is well associate

with sustainability and green construction.



Better customer perception will create better understanding and demand

and will definitely encourage developers to push for IBS adoption.

3.2.11 loose supply chain integration

Construction is a multi-organization process, which involves client/owner,

designer, contractor, supplier and consultant. It also is a multi-stage

process, which includes conceptual, design, construction, maintenance,

replacement, and decommission. By moving construction activities

upstream from the construction site to factories where pre-assembly is

carried out, high demands will be raised on the management of the supply

chain and logistic activities (Pan et al. 2008) (Blismas, 2007) (Gibb, 2001).

In such arrangement the risk involve with any construction quality and

tolerance are also clearly identify and the party responsible for taking

corrective action is agreed from the outset of a project. Extensive

integration requires good IT tools to ensure supply chain continuity and

synchronization. Integration also includes developing supplier partnership

and establishes clear information flow using IT (Oostra & Jonson, 2007).

However, the current state of construction industry is being considered as

fragmented where the whole supply chains get their own strategy and

agenda. To worsen the situation, IT adoption in Malaysia is still low and

contribute to loose supply chain coordination and integration between

design and manufacture which is vital to IBS implementation.

3.2.12 Poor knowledge and lack of awareness

Client- According to IBS Roadmap Review (2007) report, the adoption of

IBS in Malaysia is a client driven e.g. Jaya Jusco, Tesco etc. where client

has insist on fast track construction. In housing development, client with a

good knowledge and awareness of IBS benefit will therefore encourage

appointed designers to design building in IBS.



However, lack of awareness program lead to misinterpretation and thefore

contributed to a lack of interest from the client and decision makers

(Rahman & Omar, 2006). From the client point of view, unless the were

necessary fast track project e.g Tesco, Jusco project, IBS is often

misinterpreted as high risk and expensive solution.

Designer- Lack of knowledge among the IBS designers contributes to the

project delays. Designer need extra time to produce details drawing etc.

Local Authorities - Poor knowledge among the approving authorities has

resulting misunderstanding and misinterpreting of IBS and its relation to

the current building regulation. Familiarity with IBS will expedite design

approval and it is vital to ensure successful IBS project (Construction

Industry Master Plan, 2007). The majority of the authorities nonetheless is

not aware of IBS design and often takes more time than usual to process

design approval.

Policy Makers - It is also observed by Chung & Kadir (2007) recently that

of local authorities in Malaysia are unlikely to change local building

regulation to suit IBS as the amendment will consume a lot of time and

cost.

According to IBS Mid Term Review (2007), the enforcement of Modular

Coordination (MC) trough the amendment of Uniform Building by Low

(UBBL) is yet to be implemented due to poor knowledge and awareness

on this concept among the policy makers.

Workers- Government hoped IBS would help reduce dependence on

foreign workers by 30 per cent by 2015. But most industry people don't

think IBS will greatly reduce the number of workers in the industry. IBS is

taking the problem from a job-site environment to a factory environment,"

said a senior industry insider. Pre-cast means instead of going to the job



site to cast, I'm going to the factory to do the casting and then putting them

together at the job site. So how can you do pre-cast without the wet-trade

workers. He stressed that there's still a lack of skilled local workers

because of the mismatch between the training the CIDB provides and

industry needs (NST 30/8/2008)

3.2.13 Improper planning and failed to consider IBS at t he design

stage

IBS as alternative method - At presents, the pre-casters and contracting

firm in Malaysia are involved after tender stage of the construction value

chain. IBS design needs to be addressed and plan form the design stage

to be successful adopted trough the integration of pre-caster, designer

and contracting firm and not trough proposing alternate design (IBS

Roadmap Review, 2007). As a result, a lot of IBS project in Malaysia (IBS

as alternate design) is not cost effective because the process of changing

in design requires a lot of further adjustment will rise the initial time and

cost. If IBS is considered at design stage will also solve issues related to

manufacturing, transportation and logistic that can be pre-plan ahead of

time.

Lack of proper planning on IBS - Moreover, IBS requires more coherent

structure of process planning and control from start to end of the project in

order to reach the goals and reduce defect and errors (Gibb, 2001)

(Warszawski, 1999).



"Books from Prof.Alistair G.F. Gibb; Off-site: pref abrication, pre-

assembly and modularisation and Industrialised and Automated

Building Systems : A Managerial Approach by Abraham Warszawski.

Prof.Gibb currently attached at University of Lough borough is

Frenchmen. When my first time i met him at UKTI Off site / IBS

Seminar at Kuala Lumpur in 2005. While Warszawaski from Israel, i

had never met him before" (Rfd21 @

http://buildingsystem.blogspot.com/)

The overall project should be planned in such way that as soon as the

components are manufactured, it is possible to transport it to the

construction site and assemble it. Any delays either on manufacturing floor

or construction site has severe impact on staging requirement and

production planning where components from several construction projects

are scheduled for production at the same time.

Result - There are cases, where building projects are awarded and

constructed using IBS system but were carried out with many difficulties.

The most common problems encountered are improper assembly of the

components that normally involved the beam-to-column and column-to-

base connections due to impropoer planning and coordination at design

stage (Rahman & Omar, 2006)



3.2.14 IBS appears to be more expensive compared to traditional

method

"The key technology to IBS is the preparation of pr ecast building

structure off-site, which is then brought to the co nstruction site and

assembled. This allows building to be constructed w ith minimal effort

and time at the construction site, which in turn pr ovides tremendous

cost savings to the contractors" (IBS Modular

@http://ibsmodular.blogspot.com/)

IBS appears to be slightly expensive choice over the traditional method

and not an appealing option to decision makers in Malaysia. IBS

construction requires high initial investment capital for pre-casters to

purchase new machinery, mould, importing foreign technology and wages

of skilled workers for installation process (IBS Steering Committee, 2006)

(Thanoon et al. 2003). IBS is also unattractive choice due to wide swing of

housing demand, high interest rate and unsure economic condition

(Thanoon et al. 2003).

"The potential for IBS sector in Malaysia is enormous to say the least. The

conservative estimate of the industry is approximately to RM2 billion,

making the future of the industry secure" (IBS Modular @

http://ibsmodular.blogspot.com/)

For contractor, using pre-fabricated components in IBS project require

them to procure the components in advance with requiring of paying

upfront deposit. This will give affecting the cash flow of existing payment

over project progress system. As a result, small and medium class

contractors viewed IBS as threats to their business and not as

opportunities (IBS Roadmap Review, 2007).



It appears that existing procurement and contracting system is not

‘favorable’ to both pre-caster and contractor which using IBS method.

3.2.15 Technical problem related to IBS

One of the biggest drawbacks for IBS adoption is the tendency to post

construction failure. It is much related to improper installation by untrained

constriction workforce and relatively wet climate in Malaysia.

For example, Lumut Naval Base project which consists of 29 blocks of 11-

storey apartments which was constructed in 1976 by Hazama Gumi and

supervised by FH Kocks GmBH who is the consulting engineers at that

time. The 11-storey apartments are built using pre-cast concrete walling

system. The apartments are still facing problems until today with regards

to defects caused by water penetrations and leakages largely due to the

construction joints and panel integration between the wall system and the

floor system (Anon, 2008). There's also an issue of renovation works

carried out which is constraint by the pre-cast system design and also the

M & E system. It will make IBS system not popular choice for developer

and customer because the majority of house owner in Malaysia would like

to renovate their dwelling at some point of their tenancy.

3.1.16 Mismatch between the roadmap and readiness a mong

contractors and designers.

The paper has agreed and accepted that IBS is ideal conceptualization

and simplifying construction work. However, the reality in the projects is

far from practical idealism in Malaysia. The transformation is not green a

good respond due to the unlikely construction readiness (Hamid et al.

2008). Superior construction technology requires highly skilled workers to

replace foreign workers but contractors left with no other choice.



Local workforce is reluctant to join the industry because of the issues of

low wages combined with low emphasis on occupational safety and

health. The current training program to produce new construction

workforce is still not be able to cater vast demand of the market.

As such, regardless of foreign worker policy, foreign labor to do manual

job is still badly needed by the industry and it is available abundant in

cheaper cost (Construction Industry Master Plan, 2007).

Moreover, specialized skills such as system integrator or assemblers need

intensive training and apprenticeship which require more time and

investment (Thanoon et al. 2003) (IBS Steering Committee, 2006)

(Rahman & Omar, 2006). Contractors in Malaysia are also lack of past

experience in IBS and their professional is lack of technical knowledge in

this area (Hamid et al. 2008). Hamid et al. (2008) also observed lack of

R&D, low IT adoption and limited technology availability have generally

discourage IBS take up. It also appears that most innovative system and

components or using innovative materials are based on imported

technologies which are obviously more expensive and difficult to

purchase by local contractor (IBS Roadmap Review, 2007).



CHAPTER 4.0 – RECOMMENDATIONS AND WAY FORWARD.

4.1Introduction

An early effort by the Government of Malaysia to promote usage of Industrialised

Building System (IBS) and develop an Open Building System (OBS) concept as

an alternative to conventional and labor intensive construction method has yet to

make a headway. Although members of the industry are open to the idea, a

major portion of the industry stakeholders are indifferent, perhaps due to

resistance towards change, insufficient information and lack of technology

transfer method to support feasibility of change to IBS. In this case, it has proven

that it is difficult to introduce new technologies and method in the construction

sector when compared to other sectors. According to Hervas et. al (2007)

construction sector is known as a traditional sector that can be characterised as

reluctant and even resistant to change.

4.2 Recommendation and The Way Forward

4.2.1 K-Management

As the era of the K-economy enters into it’s stride, it is obvious that Global

players competing to provide unique services, processes, materials and systems

tends to impart better quality, higher speed and competitive costs. However,

there is deep concern that the construction industry as a whole is

underachieving. It has for many years maintained the time-tested but labour

intensive traditional approach in construction and investing too little in research

and development (R&D) and training even in this knowledge era. (IBS

Digest,2006)



Technological advances shall play a major role in changing the competitive work

environment in the construction industry and in providing companies with

capabilities to successfully produce and field new products, processes and

systems. The construction industry must indulge itself in innovations and

supportive of new ways of doing things. (IBS Digest,2006)

Knowledge was the driving force behind the Industrial Age. It was somehow

subsided and nearly forgotten until the next wave arrived which is the Digital Age.

This new age has resurfaced knowledge again as one of the key dimension to

propel global growth. Hence, Knowledge Management (KM) is now an important

discipline and an essential source that our economy cannot afford to do without,

if we were to have competitive advantage and remained relevant. (IBS

Digest,2006)

In Wikipedia, KM refers to a range of practices used by organizations to identify,

create, represent, and distribute knowledge for reuse, awareness and learning

across the organization. From business standpoint, Harvard Business Review

refers KM as the way companies generate, communicate, and leverage their

intellectual assets.

(IBS Digest,2006)

We have also seen over the last ten years, highly significant event took placed

on the advancement and explosion of information and communication technology

(ICT) driven by the liberalization of global economies. This has lead to

tremendous transformation in the manner businesses are being executed. (IBS

Digest,2006)

The world is not only becoming borderless but also flatter instead of round as the

bestseller writer, Thomas L Friedman put it. Information are now highly

accessible and being exploited to an unimaginable scale.



The rat race for market positioning is as fierce as ever through the capitalization

of information, knowledge and innovation.This scenario has also lead major

economies to have greater access than ever before into countries such as India

and China to exploit its competitive resources leading to a more competitive

product and services in the marketplace. With this challenging phenomenon, it is

now overdue and absolutely critical that we need to expedite our readiness, the

know-how and competitiveness of our Malaysian Construction Industry in order

to survive and sustain; an industry which is now minus 1.6 % growth based on

2005 government statistics. (IBS Digest,2006)

The fragmented nature of our industry need to be consolidated and reconstructed

in order to realize the government’s aspirations on the National IBS Roadmap

which targets the industry to be industrialized by the year 2010. (IBS

Digest,2006)

As part of efforts to steer various sectors towards our Vision 2020, the Malaysian

government has also launched the National Knowledge-Based Economy

Masterplan which was first announced by the government in the Budget 2000.

This masterplan marks yet another key government initiative to further accelerate

the development of the nation into a knowledge-based economy. It provides

strategic framework outlining the changes to the fundamentals of the economy.

(IBS Digest,2006)

These National IBS Roadmap and Knowledge-Based Economy Masterplan have

provided a good base information related the policy targets and objectives.

However, this information alone will not progress our industrialisation effort. It is

only a reference document on policy direction. As such, strategies still need to be

formulated downstream within each sector. In doing so, we need to capture our

industry knowledge, consolidate, reconfigure and strategise to our best

competitive advantage, in order to progress. (IBS Digest,2006).



Another misconception on KM is that it is ICT oriented. ICT is purely a tool to an

end. It should not be treated as the driving factor for KM. Business strategies and

direction instead, are the true drivers for KM. With a cohesive and collaborative

effort involving government and industry, we are in position to consolidate our

fragmented industry information and ignite our latent intellectual assets. We

believe such assets do exist based on our exposure in national mega

infrastructural projects over the past 15 years as well as the world is now being

flatten with information at the press of a button. (IBS Digest,2006)

TO R

However, efforts on the ‘HOW TO’ for the National IBS Roadmap seems way

behind and need to be urgently accelerated. (IBS Digest,2006)

One of the major factor for this delay is that the industry by nature, is very much

project based instead of program based. The soft aspect has not been fully

exploited especially on the management of industry knowledge.

(IBS Digest,2006)

A knowledge based construction industry would induce a conducive environment

to propel the acceleration of our IBS Roadmap. However, current mindset on

‘information protectionism’ need to be phased out. This is very much due to the

current ‘Red Ocean’ overcrowded marketplace whereby companies are engaged

in head-to-head competition struggling to survive, let alone to sustain. (IBS

Digest,2006)

“The development of human capital, the upgrading of the mentality and

intellectual capacity of a nation is one of the biggest challenges under the Ninth

Malaysia Plan. If we wish to become a knowledge-based economy, if we wish to

be a developed country and maintain that developed status, the development of

human capital must be a priority. In the context of globalisation, high quality

human capital has become a necessity , not merely a luxury.”

YAB Dato’ Seri Abdullah Ahmad Badawi, 9MP Speech, 3 1st. March 2006



The ultimate way forward is for us to inject into ourselves intellectual knowledge

which will lead us to the Know-How by becoming the specialist within the

marketplace. This can be achieved by being more open minded, unbiased,

neutral, patriotic, passionate and aggressive in our efforts to support and

participate in the realisation of our National IBS Agenda .IBS on the other hand,

is a new industry with endless opportunities. In order to commence with this

exploration, it has to start with knowledge sharing as the new working culture

within the industry. This approach encourages investment on ‘trust’ which in turn,

will lead companies who used to be in competition, to better understand each

other and collaborate for improved market positioning in this new ‘Blue Ocean’

industry.(IBS Digest,2006)

It is only with this ‘Open Collaboration’ environment that we are able to induce

participation, develop and steer, impactful downstream strategies to support the

roadmap implementation.This effort on KM however, need to be driven from both

top and bottom ends of industry heirarchy. Apart from being policy driven, each

industry organization plays an equally crucial role in developing industry’s

intellectual capability. This effort will result in the organization to be more

specialize and therefore provides an improved strategic positioning for the

industry as a whole. (IBS Digest,2006)

Based on the above, we need to create our own speciality and niche in order to

sustain. It is only through KM that this can be achieved and therefore,

necessitates companies to review their internal organizational strategies and

methodologies(IBS Digest,2006)

The essence of KM in an organization is best put forward by Alex Bennet, former

Chief Knowledge Officer of US Department of Navy. She describes the essence

of knowledge management is built on intellectual capital, which includes human



capital, social capital and corporate capital. All three are essential components of

enterprise knowledge (see diagram) (IBS Digest,2006)

Human capital is our greatest resource. It is made up of an individual’s past,

present and future. Social capital related to communications, human and virtual

networks, relationship, collaborations, etc. As for Corporate Capital, it covers

intellectual property, corporate assets and organizational processes. Knowledge

Management can be viewed as a process for optimizing the effective application

of intellectual capital to achieve organizational objectives.(IBS Digest,2006)

The current industry however, perceived as having assets, financial capital and

staff would be sufficient to realize company objectives. It is more focus on the

tangible aspect of the organization. The crucial intangible elements were

completely overlooked and this has impacted our competitiveness (IBS

Digest,2006)

In conclusion and as way forward, we clearly need to diagnose ourselves as

individual, company, associations, industry as well as the policy makers on the

state of our readiness to persevere the demanding and exhaustive rat race for

market positioning, and most critically our existence and sustainability in this ever

challenging Global climate. (IBS Digest,2006)



CIDB believes that R&D is the way forward for developing IBS. The R&D themes

and topics for IBS are aligned to the requirements of the IBS Roadmap 2003-

2010. Although the initiatives in IBS are lead by CIDB, participation from

contractors, consultants, academia, companies and research institutes are

critical. It is a daunting task as 2010 is just around the corner. The processes and

mechanisms to accomplish the target depend on the integration and acceptance

of IBS by players.

The coming three years will be very challenging. A strategic approach will be the

way forward. As the R&D arm for CIDB, CREAM’s R&D output will geared

towards industry’s application and requirements.



4.2.2 CIMP and CREAM as strategic directions

A combination of integrated approaches and long term strategic partnering with

stakeholders tackling specific agenda on IBS’ 5M strategies are the way

forward . Well co-ordinated and planned R&D themes and titles discussed in

earlier section have to be implemented simultaneously with all players.

The content of Strategic Thrust 5 simplified in Figure 1 realized the importance of

IBS as the way forward for the construction in reducing labour dependency which

is expected to grow to 5 million people in 2010 (Utusan, 19th. June, 2005).

Despite policy and promotion of IBS, the implementation is still slow except in

Klang Valley. The common critical success factors identified to address the slow

uptake of IBS by the construction stakeholders include:

o Lack of driver/s from the construction industry stakeholders,

o Government initiatives (i.e. directives, incentives, secure projects) are

required,

o Price competitiveness

o Whole life cycle costing

o IBS Supply Chain

o Information Sharing

o One channel of implementation from Government Agency(i.e. JKR, KPKT)

o Centre of Research Excellence for the implementation of IBS

o Aesthetics

o Quality Control, speed

o Lack of knowledge on IBS



Strategic Thrust 5

In order to realize the implementation and expected target of IBS in Malaysia,

CIDB together with the stakeholders and experts have successfully published a

document titled IBS Roadmap 2003-2010 (summarized in Figure 2) as the action

plan for the industry to refer to and implement.

CIMP 2006-2015 and IBS Roadmap 2003 - 2010 are the strategic directions for

the industry to move forward. The understanding of each of the document needs

to be discussed with the stakeholders to strategize and to implement IBS.



CREAM shall take the following actions as a prerequ isite to expedite the

success of the roadmap implementation with respect to IBS:

� A long term and strategic approach of conducting research on IBS shall be

established,

� The involvement of universities, companies, organisations and research

institutes right from the onset of any IBS R&D project,

� Participation and inclusion of IBS in JKR building design, i.e. JKR IBS

Design must be incorporated in its Rekabentuk Bangunan Piawai for

Government quarters, schools and Government administrative offices.

(CREAM should discuss this matter further with JKR on any issues related

to R&D).

� Malaysian standard joints for IBS (wet or dry) must be designed and made

available for use by industry,

� CREAM initiatives to lead Centre of Research Excellence on IBS and act

as One Stop Centre for R&D are critical as this moves will consolidate the

effort to centralize and identify issues and problems first hand from

industry,

� The formation of R&D laboratory and CORE for IBS is urgent and CREAM

should initiate and take the lead,

� CREAM is to apply for double deduction status to expedite participation

from private entities as they will also benefit in getting tax rebates when

contributing research funds,

� Open Building System must be competitive in terms of cost, performance

and quality as compared to proprietary system and conventional methods

in order to be sustainable in the construction market,

� Not reinventing the wheel on R&D but to focus on IBS applied research,

� Soft issues related to IBS such as marketing, social impact, involvement of

Bumiputra contractors in vendor development programme as highlighted

in the roadmap should be taken on board at the early stage,



� A complete comprehensive study on IBS solutions encompassing the

entire value chain will ensure its success. These shall include verification,

validation and certification of process on IBS components, fabricator,

factory, erector and related skills of specialization,

� A technology transfer model via knowledge management adapted from

EU, Japan and Singapore best practices in implementing IBS will add

value and expedite the implementation process.

4.2.3 Endorsement of IBS Roadmap 2003-2010

The endorsement of IBS Roadmap 2003-2010 in Malaysia by the Malaysian

Parliament on 29th October 2003 expressed seriousness of the government and

the urgency of IBS implementation. It is a blueprint of total industrialisation of

construction industry towards achieving Open Building industry by the year 2010.

The roadmap is a comprehensive document that divided the IBS programme into

the five main focus areas that reflect the inputs needed to drive the programme

(Manpower, Materials, Management, Monetary, and Marketing) (IBS Roadmap,

2003).

The content of this roadmap is focused towards achieving the industrialisation of

the construction sector and the longer term objective of implementing Open

Building Systems concept. The key elements and activities of the roadmap are to

have a labour policy that gradually reduces percentage of foreign workers,

improve Uniform Building By- Law (UBBL), develop IBS professional courses and

IBS university syllabus, develop IBS standard plan for common use, establish

verification and certification scheme, establish vendor developing program and to

study relevant incentive to encourage IBS adoption.



Industrialized Building Systems (IBS) or off-site construction has been introduced

to cope with a growing demand of affordable housing, solving issues associated

with foreign workers and improving image, quality and productivity of construction

related services in Malaysia.

Prior that, IBS Roadmap 2003-2010 has been published by the Government of

Malaysia to guide the practitioners, government agencies and professional

bodies with the strategies and implementation plan. Construction Industry Master

Plan (CIMP 2006-2015) has also higlighted the important of IBS under Strategic

Thrust 5. Nevertheless, despite the plausible advantages and strong support

from the government, IBS adoption in Malaysia has yet to obtain a good

response. This research is one of the innitiative by Construction Research

Institute of Malaysia (CREAM) and Construction Industry Development Board

(CIDB) Malaysia to benchmark best practice in those Critical Success Factors of

IBS companies in UK and Europe.



The 5-M Strategies



4.2.4 Enforcement of the legislation, regulations, guidelines and Standards

Having identified the major impediments to the introduction of IBS in the country,

it is important to suggest measures to facilitate adoption of IBS. As we can

clearly see that lack of enforcement of the legislation, regulations, guidelines and

standards are major hindrances. Therefore the process of enforcement of

regulations needs to be done step by step to enable the IBS to be standardized

through modular coordination.

The first step is to study the current status of the construction industry in terms of

controlling the dimension of the prefabricated concrete product. The study

involves legislations, planning, design, manufacturing industry, construction

technology, surveying work and etc. The result of the study is used as a

foundation to plan for the implementation of modular coordination in IBS in

Malaysia. It is also used to formulate the National Modular Coordination Standard

MS 1064 as a basis to standardize the dimension for the design of building and

the fabricated components using metric system.

Next, the strategic planning for the implementation of modular coordination need

to be done. This strategic implementation plan needs to consider the construction

organization structure, the collaborative measures and the further improvement

that can be made to the current system practiced. This is to ensure that the

implementation of IBS using the modular coordination can be done successfully.



Then, The effort will focus on the preparation of Malaysia Standard (MS) 1064 :

Guide to Modular Coordination in Building. Currently, there are 15 parts has been

approved for implementation by the Government of Malaysia.

Lastly, the execution of modular coordination through legislation is very important

to succeed in the industrialized building programmed. The implementation of

modular coordination into the uniform Building by Law, planning standard and

the building specification need to be executed. The government department such

as public Works Department and the local authorities are responsible to

introduce modular coordination through building regulations and specifications as

soon as possible.

4.3 Successful Implementation of IBS Projects

With the advanced knowledge in computer aided design, IBS buildings can be

designed and visualised analytically prior to the actual construction. The 3-

dimensional drawings can be developed to provide accurate component

dimensions and hence ensure buildability. Erection and construction procedures

can also be simulated and properly planned with the use of computer softwares.

Feasibility studies on the different building systems can be performed without

incurring much cost. Problems during construction can also be observed and

predicted. Any rectifications to the component design can be done before the

manufacturing process. These computer tools contribute to a well-planned and

systematic IBS system.

In relation to the advancement in computer-aided design, IBS buildings built in

Malaysia in the 1990s have shown significant improvement in terms structural

performance and architectural aspects. Some of these structures have become

the showcases and even the icon of the country.



One good example is the Brickfields Secondary School 1. The school is located

in a busy and limited access site. With such construction constraints and to

expedite construction period, a building system utilising about 75% of pre-

fabricated components of precast concrete beams, columns, hollow core slabs

and solid planks were adopted. The precast concrete skeletal framed IBS system

is also widely used in many other projects. Figures 6 and 7 show the precast

concrete buildings that were built using precast concrete components of beams,

columns and slabs.



Another successful examples of IBS systems using precast concrete load

bearing wall system are Senawang Police Quarter (see (a)), teachers’ quarters in

Kuala Kangsar (see (b)) and government quarters in Putra Jaya (see F(c)). A

total of 10,000 units of teachers’ quarters were built throughout the country using

the standard structural and architectural design.



In the case of steel structures, there are also many successful IBS projects.

Figure 9 shows the KLCC convention centre, an icon building in the prestigious

Kuala Lumpur city centre. The building was built using a combination of

prefabricated steel roof truss with composite steel deck flooring system.



5.0 Conclusion

Industrialized Building Systems (IBS) or off-site construction has been introduced

to cope with a growing demand of affordable housing, solving issues associated

with foreign workers and improving image, quality and productivity of construction

related services in Malaysia. Prior that, IBS Roadmap 2003-2010 has been

published by the Government of Malaysia to guide the practitioners, government

agencies and professional bodies with the strategies and implementation plan.

Construction Industry Master Plan (CIMP 2006-2015) has also higlighted the

important of IBS under Strategic Thrust 5. Nevertheless, despite the plausible

advantages and strong support from the government, IBS adoption in Malaysia

has yet to obtain a good response.

Survey on IBS system has been conducted through out Malaysia in 1996. The

purpose of this survey is to gather information on IBS buildings in Malaysia.

Besides that, a visual inspection study was also conducted to observe of any

problems related to IBS system. IBS features potential construction system for

the future with emphasis on quality, higher productivity and less labor intensive.

Besides the aim of gradually reducing the dependency on foreign labor and

saving the country’s loss in foreign exchange, IBS provides the opportunity for

the players in the construction industry to project a new image of the industry to

be at par with other manufacturing-based industry such as the car and electronic

industries.

The adoption of IBS promises to elevate every level of the construction industry

to new heights and image of professionalism. Finally, IBS should be seen as the

modern methods of construction where modern and systematic methods of

design, production planning and mechanized methods of manufacturing and

erection are applied.



The government through CIDB has embarked the IBS Roadmap 2003-2010 that

outlines several well-thought strategies and aggressive steps to promote the use

of IBS in Malaysia To facilitate further, the government has encouraged the use

of IBS for the construction of new government quarters. Contractors adopting the

IBS system are given incentive such as levy exemption based on the percentage

of IBS usage in a project.. The government is taking the leading role in

persuading the construction industry to adopt a more systematic approach and

methodology in construction.

The effort, started in 1998, is a strategic change in the construction industry. If

IBS is adopted, efficient, clean, safe and innovative are some of the new

attributes that will be associated with the construction industry. With these

outstanding features, plus attributes such as professionally managed and

handled, workers with relevant skills, proper coordination and management as

well quality will inevitably make IBS an excellent option for those involved in the

industry to become global industry players in the international arena that

demands high quality, efficient and professional services.

INDUSTRIALISED Building System (IBS) or pre-fabricated construction has not

yet met its targeted objectives, a Construction Industry Development Board

(CIDB) official said. CIDB chairman Tan Sri Jamilus Hussein said although the

administrative structure to transform from labour-intensive construction to a more

capital-intensive sector is in place, the market has not fully embraced the

concept. "With only two years to the end of the IBS Roadmap, we are far from

achieving the objectives," he said in his keynote address at the Malaysian

International IBS Exhibition (MIIE 2009) in Kuala Lumpur on 28 January 2009.

IBS is a technique that uses pre-fabricated components or off-site installation,

where project clients and developers can benefit from reduced building material

wastages. This is because the components are made to size already. The

system will enable buildings to be developed faster and stronger, hence save



costs and time. It will also help reduce dependence on foreign workers from

320,000 now to 250,000 by 2015. Works Minister Datuk Mohd Zin Mohamed had

said that more than two-thirds of the RM9.6 billion infrastructure projects under

the Public Works Department and related agencies must use IBS.

The IBS is a strategic step to move the local construction industry further up the

value chain, transforming it into a service industry that deals with components

manufactured in factories. "To achieve the objective, industrialisation of IBS

is essential to utilise market forces to bring down prices. We must also

review the IBS scoring system and separate the data on infrastructure

fabricated components from building IBS,"



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2724-29-5

2. IBS Digest, Industrialised Building Systems Issue 1 2007

3. Rahman,A and Omar, W, Issues and Challenges in t he

Implementation of Industrialised Building Systems i n Malaysia.

4. Alashwal,A.M, Optimising Production line of IBS by using simulation

5. Chung,L.M, Implementation Strategy for IBS

6. http://www.cream.com.my/files/Summary.pdf

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df

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