“I hereby declare that I have read through this project report and to my opinion this

report is adequate in term of scope and quality for the purpose of awarding the

degree of Master of Science (Construction Management)”.

EFFECTIVENESS OF INDUSTRIALISED BUILDING SYSTEM (IBS)

IMPLEMENTATION FOR MALAYSIAN CONSTRUCTION INDUSTRY

MARDHIAH BINTI ZAWAWI

A project report submitted in partial fulfillment of the

requirements for the award of the degree of

Master of Science (Construction Management)

Faculty of Civil Engineering

Universiti Teknologi Malaysia

NOVEMBER 2009

ii  

iii  

To my beloved father and mother

En. Zawawi and Puan Karimah

Thank you for your support..

iv  

ACKNOWLEDGEMENT

In preparing this project report, I was in contact with many people,

researchers, academicians, and practitioners. They have contributed towards my

understanding and thoughts. In particular, I wish to express my sincere appreciation

to my project supervisor, Associate Professor Dr. Mohamad Ibrahim Mohamad, for

encouragement, guidance, critics and friendship. Without your continued support and

interest, this project would not have been the same as presented here.

I am also indebted to Universiti Tun Hussein Onn (UTHM) for funding my

study. My special thanks also extended to all of the interviewee and other

respondents for the time and kindness in answering the questionnaire and also for

those who helped to revise this paper.

My sincere appreciation also extends to all my colleagues and others who

have provided assistance at various occasions. Their views and tips are useful indeed.

Unfortunately, it is not possible to list all of them in this limited space. Last but not

least, I am grateful to all my family members.

v  

ABSTRACT

Generally, the used of Industrialised Building System (IBS) in construction

industry throughout the world has positive perceptions on improving the overall

construction industry performance. Therefore, Construction Industry Development

Board (CIDB) has been actively promoting the use of Industrialised Building System

(IBS) in Malaysian Construction Industry since 1998. Unfortunately, the used of IBS

for building project in Malaysia is still limited if compared to CIDB’s target. In view

to this limitation, this study has been carried out to evaluate the effectiveness of

current IBS implementation for Malaysian construction industry through the

measurement of acceptance level on the current IBS implementation and also

determination of the existing problems faced by construction industry related to the

IBS implementation. The methodologies adopted for this study are interview with

expert panels and questionnaire survey. The result of this study revealed that current

promotion on IBS for awareness purposes is effective but unfortunately the

application is still very limited since it only covers certain elements. Not all

practitioners can accept it implementation especially company and personnel with

less experiences in handling IBS project. It is recommended that the relevant

institution which produce young engineer for construction sector must provide a

syllabus on IBS which cover technical, business process, and all aspect which needed

for effective IBS implementation. This can generates wider range of application of

IBS product within the industry.

vi  

ABSTRAK

Secara umumnya, penggunaan Sistem Bangunan Berindustri (IBS) di dalam

industri pembinaan meraih pandangan yang positif dalam meningkatkan prestasi

industri pembinaan secara keseluruhannya. Oleh itu, bermula tahun 1998, Lembaga

Pembangunan Industry Pembinaan (CIDB) telah mempromosikan penggunaan IBS

di Malaysia secara aktif. Walaubagaimanapun, penggunaan IBS di Malaysia masih

lagi tidak mencukupi jika dibandingkan dengan hasrat CIDB. Merujuk kepada

kekurangan tersebut, kajian ini telah dijalankan untuk menilai keberkesanan

perlaksanaan IBS bagi industri pembinaan Malaysia melalui penilaian tahap

penerimaan terhadap perlaksanaan IBS dan juga penentuan masalah yang dihadapi

oleh industri pembinaan berhubung dengan perlaksanaan IBS. Kaedah yang

digunakan dalam menjalankan kajian ini adalah temubual bersama panel pakar dan

borang soal selidik. Hasil kajian telah mengesahkan bahawa perlaksanaan promosi ke

atas IBS untuk tujuan kesedaran yang dijalankan sekarang adalah berkesan tetapi

malangnya penggunaannya masih lagi terhad kerana hanya merangkumi beberapa

elemen sahaja. Tidak semua pengamal industri pembinaan boleh menerima

perlaksanaannya terutamanya syarikat dan individu yang kurang pengalaman dalam

mengendalikan projek IBS. Saranan telah dibuat agar institusi yang mempunyai

pengaruh dalam menghasilkan jurutera muda supaya seharusnya menyediakan silibus

berkenaan IBS yang merangkumi teknikal, proses perniagaan, dan segala aspek yang

diperlukan untuk perlaksanaan IBS yang lebih efektif. Ini bagi menghasilkan

aplikasi produk IBS yang lebih meluas dikalangan industri ini.

vii  

TABLE OF CONTENTS

CHAPTER

TITLE PAGE

DECLARATION ii

DEDICATION iii

ACKNOWLEGEMENT iv

ABSTRACT v

ABSTRAK vi

TABLE OF CONTENTS vii

LIST OF TABLES xii

LIST OF FIGURES xiv

LIST OF APPENDICES xvi

1 INTRODUCTION 1

1.1 Introduction 1

1.2 Problem Statement 3

1.3 Research Aim and Objective 3

1.4 Research Sampling 4

1.5 Scope of Study 4

1.6 Brief Research Methodology 5

2 INDUSTRIALISED BUILDING SYSTEM 7

2.1 Introduction 7

2.2 Definitions 7

viii  

2.3 Characteristic of IBS 8

2.4 Types of IBS 9

2.4.1 Precast Concrete 11

2.4.1.1 Production Processes 11

2.5 Advantages 12

2.6 Summary 13

3 CURRENT INDUSTRIALISED BUILDING

SYSTEM (IBS) IMPLEMENTATION

14

3.1 Introduction 14

3.2 Critical Success Factor in Implementing IBS 15

3.2.1 Demand and Market Factor 16

3.2.2 Government Initiatives 17

3.2.3 Availability of IBS Expertise 17

3.3 IBS in Practitioners Perspective 18

3.3.1 Manufacturer Perspective 19

3.3.2 Client Perspective 19

3.3.3 Consultant Perspective 20

3.3.4 Contractor Perspective 21

3.4 Conventional Project Implementation 21

3.5 CIDB Roles Through IBS Centre 22

3.6 IBS Implementation 24

3.6.1 System Involved in IBS Implementation 25

3.6.1.1 Project Delivery System 25

3.6.1.2 Design System 25

3.6.1.3 Logistic Management System 25

3.6.1.4 Standard and Regulation 26

3.6.2 IBS Implementation in other Country 27

3.6.3 IBS Implementation in Malaysia 29

3.7 Summary 29

4 RESEARCH METHODOLOGY 30

4.1 Introduction 30

ix  

4.2 Literature Review 30

4.3 Interview with Expert Panels 31

4.3.1 Design of the Structured Open Ended

Questions

31

4.4 Questionnaire Survey 33

4.4.1 Design of Questionnaire Survey 33

4.4.1.1 Sections of the Questionnaire

Survey

35

4.5 Data Analysis 34

4.5.1 Content Analysis 35

4.5.2 Frequency Analysis 35

4.5.3 Average Index Analysis 36

4.5.4 Independent Sample Test 37

4.6 Summary 37

5 RESULTS AND DATA ANALYSIS 38

5.1 Introduction 38

5.2 Structured Interview 38

5.3 Questionnaire Survey 43

5.3.1 The Respondents Profile 44

5.3.2 Experience on IBS Project 45

5.3.3 Company Experience 46

5.3.4 Company Contract Value 47

5.3.5 Respondent Personal Experience 48

5.4 Level of IBS Acceptance in Malaysian

Construction Industry

50

5.4.1 Acceptance Level versus Experience on

IBS Project

52

5.4.2 Acceptance Level versus Company

Experience

53

5.4.3 Acceptance Level versus Company

Contract Value

54

5.4.4 Acceptance Level versus Respondent 55

x  

Personal Experience

5.5 Root Problems in IBS Implementation 56

5.5.1 Root Problems versus Experience on IBS

Project

58

5.5.2 Root Problems versus Company

Experience

59

5.5.3 Root Problems versus Company Contract

Value

61

5.5.4 Root Problems versus Company Type 63

5.5.5 Root Problems versus Respondent

Personal Experience

64

5.6 Strategy for Better IBS Implementation 67

5.6.1 Strategy versus Experience on IBS

Project

69

5.6.2 Strategy versus Company Experience 71

5.6.3 Strategy versus Company Contract Value 72

5.6.4 Strategy versus Company Type 73

5.6.5 Strategy versus Respondent Personal

Experience

74

5.7 Summary 75

6 DISCUSSION OF RESULTS 76

6.1 Introduction 76

6.2 Level of Acceptance and Awareness 77

6.3 Problems with IBS Implementation 79

6.4 Suggestion on Strategies and IBS Implementation 82

7 CONCLUSION 85

7.1 Introduction 85

7.2 Objective versus Findings 85

7.2.1 To Determine the level of IBS acceptance

in Malaysian construction industry

86

xi  

7.2.2 To evaluate the problems of IBS

implementation in Malaysian construction

industry

86

7.2.3 To develop a strategy for better IBS

implementation

87

7.3 Study Evaluation and Limitation 87

7.4 Future Research Perspectives 87

REFERENCES 89

Appendices A – C 92-113

xii  

LIST OF TABLE

TABLE NO.

TITLE PAGE

5.1 Content analysis for acceptance level

39

5.2 Content analysis for root problems

40

5.3 Content analysis for suggestion on strategies

42

5.4 Level of IBS acceptance among all practitioners

51

5.5 Problems faced by practitioners in general

56

5.6 Rank analysis of root problems on different IBS experience

58

5.7 Statistical test on root problems on different IBS experience

58

5.8 Rank analysis of root problems on different company experience

60

5.9 Statistical test on root problems based on company experience

61

5.10 Rank analysis of root problems on different company contract value

62

5.11 Statistical Test of root problems on different company contract value

62

5.12 Rank analysis of root problems on different type of company

63

5.13 Statistical Test of root problems on different type of company

64

5.14 Rank analysis of root problems on different respondent personal experience

65

xiii  

5.15 Statistical test of root problems on different respondent personal experience

66

5.16 Strategies rank by respondent in general

67

5.17 Rank analysis on strategies via different experience on IBS project

70

5.18 Statistical test on strategies via different experience on IBS project

70

5.19 Rank analysis on strategies via different company experience

71

5.20 Statistical test on strategies via different company experience

72

5.21 Rank analysis on strategies via different company contract value

72

5.22 Statistical test on strategies via different company contract value

73

5.23 Rank analysis on strategies via different type of company

73

5.24 Statistical test on strategies via different type of company

74

5.25 Rank analysis on strategies via different respondent personal experience

74

5.26 Statistical test on strategies via different respondent personal experience

75

6.1 Results on Kruskal Wallis 82

xiv  

LIST OF FIGURE

FIGURE NO.

TITLE PAGE

1.1 Brief Research Methodologies

6

2.1 Precast concrete framing and wall systems

9

2.2 Steel formwork system

10

2.3 Steel framing system and roof trusses

10

2.4 Prefabricated timber framing system

10

2.5 Types of concrete masonry units

11

5.1 Breakdown of respondents based on company financial capabilities

44

5.2 Breakdown of respondents based on respondent personal experience

45

5.3 Breakdown of respondents in count based on company type and experienced on IBS project

46

5.4 Breakdown of respondents in count based on company type and company experience in industry

47

5.5 Breakdown of respondents in count based on company type and company contract value

48

5.6 Breakdown of respondents in count based on company type and respondent personal experience

49

5.7 Acceptance level of respondents grouped by company’s experience on IBS project

52

5.8 Acceptance level of respondents grouped by company’s experience in industry

53

xv  

5.9 Acceptance level of respondents grouped by company contract value

54

5.10 Acceptance level of respondents grouped by respondent personal experience

55

6.1 Problems of cost rising due to converting design

80

6.2 Distribution of respondents agreed on high price of IBS component

81

xvi  

LIST OF APPENDICES

APPENDIX

TITLE PAGE

A Question for Expert Panels 92

B Technical Paper 94

C Questionnaire Survey 107

 

1  

CHAPTER 1

INTRODUCTION

1.1 Introduction

Through globalisation, so many information, knowledge, and technology can

be shared and transferred easily across countries. Industrialised Building System

(IBS) is one of the technologies which can be categorised as an old technology in

developed country but yet considered as a new technology when reached developing

countries such as Asian region.

Although the implementation of IBS in Malaysia has started since 1960’s, it

is only become popular in 1998 when Cabinet of Ministers endorsed IBS Strategic

Plan as the blueprint for the total industrialisation of construction sector. Since the

time, Construction Industry Development Board (CIDB) has been actively promoting

the use of IBS in Malaysian Construction Industry. First step taken by CIDB was

formulating IBS Roadmap which stated several strategies and aggressive steps to

promote the used of IBS in Malaysia. The main purposes of introducing IBS at that

time were to gradually reduce the dependency on foreign labours and to increase

productivity.

Over past decade, the level of IBS usage is still very low even though its

implementation has started since early 1960’s in Malaysia. Construction industry

practitioners seem like reluctant to use IBS as their construction method. In spite of

that, Warszawski (1999) highlighted that by adopting IBS, some saving in manual

2  

labour on-site can be achieved, increasing construction speed and providing higher

construction quality. Thanoon et al. (2003) also underlined cost saving, faster

construction time and improvement of overall construction quality as the result of

IBS implementation. From evidences provided, it can be concluded that, the used of

IBS so far gained a good reputation among the researchers in general, which fulfil

the basic goal of construction; time, resources and quality.

Due to this circumstance, several studies have been done. Badir (2002) for

example has studied on building system technologies in Malaysia and examined

problems and constraints associated with this technology. The study concludes that

the problems related to IBS technology were the higher initial capital investment and

the needs for expert labour to deal with heavily mechanised approach in IBS.

Therefore, extra cost was needed to train existing semi skilled labour to be highly

skilled labour.

On the other hand, Chung (2007) has investigated on current awareness of the

usage of IBS in Malaysia. Moreover his study has analysed ways to improve the

implementation of IBS in terms of the current policy and guideline available to

implement the usage of IBS in the local construction industry. The study focused on

the usage of 50% of the IBS elements in terms of cost. The Strength, Weakness,

Opportunity and Threat (SWOT) Matrix has been used when analysing the current

scenario in the local construction industry and therefore the strategic implementation

plan has been suggested in his study which stated government need to provide a

governing body that is only in charge of the legislations, training, financing,

controlling, research and development so that an effective strategy can be formulated

and applies to all the parties involved.

Apart from that, critical success factor in adopting IBS for Malaysian

Construction Industry has been studied by Noriwani (2008). The study focused on

success factors and barriers for IBS adoption in Malaysian building construction

industry. The information and data gathered through questionnaire and then

processed using average index method. Based on the study, she has determined the

most critical success factors in adopting IBS as meeting flexibility in choosing

components, meeting client expectancy, and ensures market security for a long term.

3  

Meanwhile, in technical aspect, providing clear design process was the critical factor

in successful IBS adoption.

1.2 Problem Statement

IBS appears as the most suitable system to overcome several problems in

construction industry especially overused of foreign labour and low productivity rate.

Unfortunately, the level of IBS usage in local construction industry is only 15% in

2003 (CIDB, 2003a). In 2006, only 10% which is less than one third of total

completed construction project using at least one IBS product (CIDB, 2007).

Moreover, Tan Sri Dato’ Ir. Jamilus Hussein has stressed in his speech in

Malaysian IBS International Exhibition 2009 that construction industry are still far

from achieving the ideal objective as articulated in IBS Roadmap even though almost

all activities identified in the roadmap has been implemented. Based on the

Roadmap mid-term review, it is clearly stated that one of the most barriers is

negative perception by the consumer and the practitioner. Even contractors whom

experiences in IBS construction project before, reluctant to use IBS in their next

project. Why is this so?

Do Malaysian Construction practitioner acceptances on IBS implementation

inline with the researcher studies and government hope? If not, probably there is

some gap between the IBS and construction industry which resulted on various

problems when IBS is being implemented.

1.3 Research Aim and Objective

The aim of the study is to evaluate the effectiveness of current IBS

implementation for Malaysian construction industry. To achieve this aim, the

following objectives have been identified:

4  

i. To determine the level of IBS acceptance in construction industry.

ii. To evaluate the problems of IBS implementation in construction

industry.

iii. To develop a strategy to promote the use of IBS in Malaysian

Construction Industry.

1.4 Research Sampling

The construction industry in Malaysia consists of three main groups namely

Client (owners and developers), Consultants (architects, engineers, surveyors), and

Contractors (building and civil contractor). Basically, Client as the owner/developer

is the organisation that will decide whether to use IBS or not. Thus, Client will

appoint Consultants comprising planners, architects, engineers, surveyors who will

convert Client intention to a project design by referring the existing IBS tools. The

tools comprises IBS catalogues, Modular Coordination guideline, MS1064 standard,

and etc. Finally Contractor will construct the building according to the consultants’

drawing and specification by applying their knowledge and experiences. As far as

IBS work is concern, manufacturer becomes one of the important groups in

construction industry as the fabricator and supplier of the component. For the

purpose of this study, the sample will be chosen randomly according to the four

groups explained above within limitation and scope assigned below.

1.5 Scope of Study

Random sampling will be done in assigned area, whom practicing

Conventional Construction Method and Industrialised Building System Method.

There are some limitations for this study;

i. The information and data taken only covers projects within 2005 until

now

ii. Only covers IBS superstructure using precast concrete systems

5  

iii. Area for data collection confine within states of Johor, Melaka,

Negeri Sembilan and Selangor

1.6 Brief Research Methodology

The study was conducted using literature method, interviews with expert

panels and questionnaire survey. A literature search was carried out as preliminary

study in gaining information about recent strategies, problems and challenges in

implementing IBS. It is done by referring to many sources such as published books,

articles in books, journals and papers, other published research works, academic and

research magazines, newsletter, brochures and information from the internet. Then

only followed by interviews with expert panels and distributing questionnaire survey.

Figure 1.1 explains the brief methodologies used in this study.

6  

RESEARCH METHODOLOGY

ACTIONS OBJECTIVES

Stage 1: Research tools 1. Search secondary data

Secondary data

- search for IBS and Malaysian construction industry concept in general

To understand what IBS and MCI is all about

- review of IBS implementation being practice nowadays

To understand the existing IBS implementation strategy being used

- review IBS implementations in other country

To find out any better way to implement IBS

2. Survey Questionnaires

To identify IBS level of acceptance

Survey - Develop survey questionnaires

Questionnaire - Select sample frame

- Determine the sample size for the survey

To evaluate any problems occur due to existing IBS implementation

- Determine the response rate 3. Interview Experts

Interview Experts

- Develop a structure interview content

To evaluate the effectiveness of existing IBS implementation plan

- Determine which company to interview

- Process structure interview - Time schedule and others

To find out any good ideas for better IBS implementation

To develop new strategy to improve IBS in Malaysia

Stage 2 : Develop new IBS implementation strategy

- Together with secondary data, survey, and interview findings to develop a new IBS implementation strategy for Malaysian Construction Industry

To develop new IBS implementation strategy for Malaysian Construction Industry

Figure 1.1: Brief methodologies

7  

CHAPTER 2

INDUSTRIALISED BUILDING SYSTEM

2.1 Introduction

This chapter will cover basic theories on industrialised building system such

as definitions, characteristics, types of IBS, and advantages. This information is

important to improve understanding on Industrialised Building System in general.

2.2 Definitions

To date, there are various definitions of IBS interpreted by researchers.

Among the earliest one is Junid (1986) who described IBS as process by which

components of building are conceived, planned and fabricated at factory, transported,

and erected at site. The system combined software and hardware, including system

design, which is complex process of studying the requirement of end user, market

analysis, and the development of standardize component. Parid (1997) defined IBS

as a system which use industrialised production technique either in the production of

component or assembly of the building or both.

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

8  

  

equipment. The components are manufactured offsite and once completed will be

delivered to construction sites for assembly and erection. Chung and Kadir (2007)

defined IBS as a mass production of building components either in factory or at site

according to the specification with standard shape and dimensions and transport to

the construction site to be re-arranged with certain standard to form a building.

Nonetheless, IBS Roadmap (2003) defined IBS as a construction process that

utilises techniques, products, components, or building systems which involved

prefabrication works (off-site of on-site) under controlled environment, transported,

positioned, and on-site installation with minimum site works.

2.3 Characteristic of IBS

To date, there are various characteristic of IBS identified by researchers.

Among the accepted one is stated by Thanoon et al (2003) which consist of closed

and open system, modular coordination, standardization and tolerance, mass

production, specialization, good organization, integration, production facilities,

transportation, and equipment.

According to Warszawski (1999), IBS can be characterised as prefabrication

of as much as possible building elements and components offsite, within central

facilities through specialised equipment and organization. Then the components will

be assemble to site, and involved extensive mechanized handling with minimum

task. A part from that, IBS involved integrated design, production and erection work

on site which needs to be planned and coordinate accordingly.

Considering the above characteristics, CIDB (2003b) have summarised IBS

characteristics as;

i. Industrial production of components through prefabrication or highly

mechanised on site processes

ii. Reduced labour usage both at prefabrication stage and onsite work.

2

t

iii.

iv.

v.

2.4 Type

IBS

the system w

i.

ii.

Modern

Design (C

Applying

project im

Open Bu

to standa

es of IBS

can be class

which are;

Type 1: P

precast c

permanen

Figur

Type 2:

systems,

formwork

design and

CAD) and C

g Systematic

mplementatio

uilding system

rdization, to

sified into fi

Precast Conc

concrete col

nt concrete f

e 2.1: Precas

Steel Form

beams and

ks

 

manufacturi

Computer Ad

c Quality Co

on

m which allo

olerance and

five common

crete Framin

lumns, beam

formworks, e

st Concrete F

mwork Syste

columns m

ing method

dded Manufa

ontrol throu

ows hybrid a

modular coo

n types base

ng, Panel and

ms, slabs, w

etc.

Framing and

em – includ

moulding for

through Com

acturing (CA

ghout the pr

application,

ordination.

d on structu

d Box Syste

walls, “3-D”

d Wall Syste

des tunnel f

rms, and pe

mputer Aide

AM)

rocess of IB

and adaptab

ural aspects

ems – includ

” component

ems

forms, tillt-u

ermanent ste

9 

ed

BS

ble

of

des

ts,

up

eel

v

iii.

iv.

v. Type

and l

Type 3:

frame sys

Fig

Type 4: P

trusses, b

Fig

e 5: Block w

lightweight c

Figu

Steel Fram

stems, roof t

ure 2.3: Stee

Prefabricated

beam and col

gure 2.4: Pre

work System

concrete blo

 

ure 2.2: Stee

ing System

trusses, etc.

el Framing S

d Timber Fr

lumns, roof

efabricated T

ms – includes

ocks.

el Formwork

– Steel be

System and R

raming Syste

trusses, etc.

Timber Fram

s interlockin

k System

ams and co

Roof Trusse

em – Prefabr

ming System

ng concrete m

1

olumns, port

s

ricated timb

masonry uni

10 

tal

ber

its