CHAPTER 2

INDUSTRIALIZED BUILDING

SYSTEM (IBS) IN MALAYSIA

CHAPTER 2

INDUSTRIALIZED BUILDING SYSTEM (IBS)

2.0 DEFINITION OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

Before defining what Industrialized Building System (IBS) means, it is better to

understand the meaning of the “Industrialization”. According to Wikipedia (2007),

Industrialization means a process of converting to a socioeconomic order in which

industry is dominant. In relation to the construction industry, the term refers to a method

of technological advancement applied in construction process which employed from

manufacturing industry” (Warszawski, 1999). Warszawski (1999) further says that

subsequent automation and prefabrication are the concept of industrialization in

manufacturing process and has been inhibited to the construction industry since the 18th

century. In the late 1900’s, the process of industrializing the construction industry has

introduced a new form of construction system so called “Industrialized Building

System” (IBS) which not only regards to the construction and production itself but also

the aspect of informative technology, economical , coordination and management ( Roy,

Low & Waller, 2005).

The general definition of IBS covers all types of structure, as the word “building”

actually relates to “constructing”. According to Warszawski (1999), IBS can be defined

as:

“Construction systems in which components are manufactured in a factory, on or off

site, positioned and assembled into a structure with minimal additional site works”

In addition, Gibb (1999) described IBS literally as “assemble before”. IBS or

prefabrication/pre-assembly covers the manufacture and assembly (usually off-site) of

buildings or parts of buildings or structures earlier than they would traditionally be

constructed on site, and their subsequent installation into their final position (Gibb,

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1999).For the purpose of this research, the definition asserted by Thanon, Samad, Kadir

and Ali (2003) will used as it is comprehensive and conclusive. According to Thanon et

al (2003), IBS be defined as an industrialized process by which components of a

building are conceived, planned, fabricated, transported and erected on site. Thanon et

al (2003) added that the systems include system design, which is a complex process of

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

components, establishment of manufacturing and assembly layout and process,

allocation of resources and materials, conceptual framework and management.

2.1 HISTORY OF INDUSTRILIZED BUILDING SYSTEM (IBS)

2.1.1 International

According to Warszawski (1999), the idea of industrializing building components is not

new and can be traced back to early 1624 when panelized timber houses were shipped

from England to the new settlement in North America. The Industrial Revolution of the

1700’s provided the construction industry with technological boost (Warszawski, 1999).

He claimed that the construction of the first cast iron bridge across the Severn Gorge, at

a place now known as Iron Bridge in Shropshire, England revolutionized the way

structures were built.

After that, various outstanding iron-based structures were constructed: including the

modular-dimensioned Crystal Place in Hyde Park, London for the 1851 Great

Exhibition and the Eiffel Tower for the Paris World Expo and French Revolution

centenary Celebration in 1889 (Warszawski, 1999). According to Tatum (2000), the

development of steel and other pre-engineered materials promoted the race to build tall

structures, particularly in the United States where steel frames are often combined with

pre-cast panels in building skyscrapers.

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2.1.2 Malaysia

According to Thanon et al (2003), the idea of using industrialized building system in

Malaysia was first mooted during the early sixties when the Minister of housing and

Local Government visited several European countries and evaluated their building

systems performance. Thanon et al (2003) added that, through the visit, the government

took a brave decision to try two pilot projects which were the Pekeliling Flats in Kuala

Lumpur and the Rifle Range Road Flats in Penang using IBS concepts. According to

Thanoon et al (2003), the first pilot project was constructed on 22.7 acres of land along

Jalan Pekeliling which included the construction of 7 blocks of 17-storey flats and 4

blocks of 4-storey flats comprising about 3000 units of low cost flats and 40-storey shop

lots. The project was awarded to the Gammon/Larsen Nielsen using the Danish System

of large panel industrialized prefabricated systems.

Meanwhile, the second pilot project was built in Penang with the construction of 6

blocks of 17-storey flats and 3-blocks of 18-storey flats comprising 3,699 units and 66

shop lots along Jalan Rifle range. The project was awarded to Hochtief / Chee Seng

using the French Estiot System (Thanon et al, 2003). Following these pilot projects,

Perbadanan Kemajuan Negeri Selangor (PKNS) between the years 1981 and 1993 had

acquired pre-cast concrete technology from Praton Haus International, Germany and

involved in numerous housing projects ranging from low cost houses to high cost

bungalows (Eddie, 2005).

According to Sharul (2003), the uses of IBS have increased, particularly during the

years 1995-1998 which include the construction of the Bukit Jalil Sports Complex and

Games Village, the Petronas Twin Towers and the LRT lines and tunnels. He added that

other projects include the construction of elevated highways using pre-cast concrete box

girder as well as the monorail lines utilizing arched pre-cast concrete beams. However,

it appears that the usage of IBS in Malaysia is still low compared to that of other

developed countries such as Japan, UK, Australia and the United States of America

(Sharul, 2003).

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2.2 TYPES OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

Based on the structural aspects of the systems, IBS can be divided into five common

types which are currently available in Malaysia (CIDB, 2005).

i. Precast Concrete Components System

ii. Steel Framing Systems

iii. Steel/Alumnium Formwork Systems.

iv. Prefabricated Timber Framing Systems

v. Blockworks Systems

2.2.1 Precast Concrete Components System

Precast Concrete Component System is one of the IBS construction systems which are

mainly used for local building infrastructure projects (IBS Survey, 2003). Precast

components come in a variety of shapes for different types of usage, both architectural

and structural. It includes the traditional precast beams, columns, slabs, walls,

staircases, parapets and drains; as well as other relatively new precast components for

toilets, pile caps, facades, lift shafts and refuse chambers.Precast concrete components

produced either in factory based production (close and open site casting ) or on site

cast ( open site).

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Figure 2.0- Types of precast concrete component available in local market

Source: CIDB (2005). “Precast Concrete Construction” IBS Digest -1 ,p.11-14

In building projects, CIDB (2005) indicates that precast concrete components can be

categorized into (3) three main types which are:

1. Framing system

2. Wall system

3. 3-D Components

2.2.1.1 Framing System – Column, beam, slab etc

This IBS system is suitable for buildings that need a high degree of flexibility in terms

of larger clear distances between columns. As a result, the longer spans give bigger

open span and greater freedom for designing the floor areas. The system can be used for

buildings that offer a certain luxury of space such as in the case of office buildings,

school buildings, hospitals, university buildings, commercial buildings and car parks.

Therefore, the system normally chosen for any type of building is because of its

common requirement, such as:

• Requirement with respect to comfort such as a spacious area

• Flexibility for future modification

• Ample floor-to-floor clearance height

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Figure 2.1- Precast Concrete Beam

Figure 2.2- Precast Concrete Column

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Figure 2.3 – Precast Concrete Hollow Slab

Source: Catalogue, Eastern Pretech Sdn Bhd (2008)

2.2.1.2 Wall System

Precast concrete wall building is a system in which the structural framework of the

building is composed of precast concrete slabs and load bearing walls. This system is

preferred for the construction of simple and uncomplicated buildings such as hotels,

hostels and government apartments such as teachers’ quarter. These buildings normally

offer a lesser degree of flexibility in which major modifications, such as the removal of

load-bearing walls, are restricted during their service life. CIDB (2005) stated that there

are (3) three classes of precast concrete walls namely:

1. Load bearing wall

Load bearing walls are structural elements that carry vertical load from slabs to

the foundation.

2. Shear wall

Walls taking lateral loads from wind or earthquake are normally referred to as

shear wall.

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3. Partition wall

Partition walls are used to divide the area of a room into several functions and

categorized as non-structural elements, and may be removed if required.

Figure 2.4- Precast Concrete Internal Wall

Figure 2.5 – Precast Conc. External Wall

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Figure 2.6- Erection process of wall panel

Source: IBS Road Show 2005, Architect branch of PWD

2.2.1.3.1 3-D Components

The examples for this type of precast component systems are balconies, staircases,

toilets, lift chambers, refuse chambers etc.

Figure 2.7- Precast Concrete Staircase

Source: Catalogue, Eastern Pretech Sdn Bhd (2008)

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2.2.2 Steel Framing System

Steel Framing System is one of the IBS components available in Malaysia. According

to Watson (2003), steel framing has become a very innovative industry with technical

developments leading to high quality housing construction at a very competitive price.

Steel has been used for more than 150 years in shaping the built environment. Although

the idea of steel conjures up images of a heavy or cumbersome material, the steel used

in residential construction is quite the opposite. Cold-formed steel is lightweight, easy

to handle, cost effective, and a high quality alternative to traditional residential framing

materials. Steel offers the builder a strong, dimensionally stable, easy-to-work framing

system. There are three basic residential steel framing methods: stick-built, panelized,

and pre-engineered.

1. Stick-built

Replace wood members with steel members (one-for-one). As shown below in Figure

2.8, the steel-framed non-load-bearing wall appears very similar to that of a comparable

wood-frame.

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Figure 2.8 – Steel stilt-up framing method

Source: http://www.toolbase.org/Construction-Methods/Steel-Framing/designing-homes-cold-formed-steel

2. Panelized

Factory-assembled panels delivered to site and assembled. The panelized approach

represents an efficient approach for repetitive building designs and, as a result, is a

popular approach in hotel/motel construction and other multi-unit applications i.e. floor

frame.

3. Engineered

Location and placement of framing members is engineered to take advantage of steel’s

properties. Spacing of framing members may increase to as much as 8-feet (2-3 meters)

with horizontal stabilizers.

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According to Watson (2003), the most widely adopted method is that of factory

prefabrication of floor frame units, wall frame units, and roof trusses of transportable

size, which are then assembled and erected in place on site. Meanwhile, the less popular

approach is to deliver the pre-cut straight members to site and carry out all fabrication

and assembly on site for instance structural steel frame (NASH, 2003).

Figure 2.9- Steel-framed wall

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Figure 2.10- Steel floor frame

Figure 2.11- Steel roof trusses

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Figure 2.12- Steel structural frame

Figure 2.13- Steel structural frame (column and beam)

Source: http://www.toolbase.org/Construction-Methods/Steel-Framing/designing-homes-cold-formed-steel

Commonly used with pre-cast concrete slabs, steels columns and beams, steel framing

systems have always been the popular choice and used extensively in the fast-track

construction of skyscrapers. Recent development in this type of IBS includes the

increased usage of light steel trusses consisting of cost-effective profiled cold-formed

channels and steel portal frame systems as alternatives to the heavier traditional hot-

rolled sections.

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2.2.3 Steel / Aluminum Formwork System

According to Sharul (2003), Steel/aluminium formwork system is considered as one of

the “low-level” or the “least prefabricated” IBS, as they generally involve site casting. It

can be reused more than 500 times which results in higher productivity, efficiency,

economy and quality. The usage of Formwork systems has now become a trend in the

Malaysian construction industry, especially for high rise buildings (CIDB, 2005).

Recognized as one of the Industrialised Building Systems (IBS), Formwork system

simplifies the whole construction process by enabling a smooth and fast operation that

can result in cost effectiveness, productivity and high quality finished. Formwork

systems have proven that impressive results can be achieved in terms of productivity,

efficiency, economy and quality (CIDB, 2005). It can usually be reused for 500 to 1,000

times, and is an effective way to construct buildings that have repetitive elements or

layouts. The system is now one of the most preferred methods of cellular construction

by the contractors in Malaysia whilst clients appreciate formwork system ability to

deliver projects to budget and on time. The types of formwork system are include -

tunnel forms, tilt-up systems, beams and columns moulding forms, and permanent steel

formworks (metal decks).

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Figure 2.14- Aluminium mould for column

Figure 2.15- Column and beam formwork

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Figure 2.16- Tunnel formwork

Figure 2.17- Tilt-up formwork system

Source: PECB (2007),” Presentation on PECB experience in IBS construction system”

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2.2.4 Prefabricated Timber Framing System

The most dominants components in fabricated timber are timber building frames and

timber roof trusses (Rozaimah, 2004). According to Sharul (2003), it is estimated that

across all the developed countries, timber frame accounts for around 70% of all housing

stock, representing some 150 million homes. He also stated that, in terms of

sustainability, timber is possibly the only renewable resource in the construction sector

and contains less embodied energy than comparable building materials. Palmer (2000),

Rozaimah (2004) and Eddie (2005) also noted that, there are 3 main methods of timber

framing system namely, which are:

1. Stick built

Components cut off-site and assembled on-site using simple hand tools.

2. Hand erect (Small panel)

Components are assembled off-site in timber frame factories.

3. Crane erects (large panel or whole-room).

Similar to small panel only the panels can be up to 9.6 meters long and require a

crane to erect them as they are too heavy to maneuvers by hand. Crane erect also

enables the use of whole-room construction or volumetric techniques.

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Figure 2.18- Timber frame for wall

Figure 2.19- Prefabricated timber roof truss system

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Figure 2.20- Joint of prefabricated timber roof truss system

Source: CIDB (2004)” Timber framing as Industrialised Building System (IBS)”

Among the products listed in the figures shown above is the timber building frames and

timber roof trusses. While the latter is more popular, timber building frame systems also

have their own good market; offering interesting designs from simple dwelling units to

buildings that require high aesthetical values such as chalets for resorts. According to

Eddie (2005), the timber framing system that is usually used in Malaysia is the

prefabricated timber roof truss system, specifically in public projects.

2.2.5 Blockwork system

Block work system usually refer to the interlocking concrete masonry units (CMU) and

lightweight concrete blocks is applied to replace the construction method of using

conventional bricks where it save in term of time compare to time-consuming

traditional brick-laying tasks (Sharul, 2003). CMU or the aforesaid blocks are available

in various grades and sizes to cater for most building design requirements. Maximum

productivity is achieved by the use of large format blocks system, which are sufficiently

lightweight for easy handling.

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Block work system can be used in a number of applications including the inner leaf of

cavity walls, party walls and partitions. It is also well suited to external solid walls

where the productivity gains are equally applicable. CMU or lightweight concrete

blocks system walls can be finished externally in a variety of ways including insulated

render and brickwork as well as traditional cladding materials.

Figure 2.21- Lightweight blocks

Figure 2.22- Blockworks system approach

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Figure 2.23- A house being constructed through blockworks system

Source:Matthew(2006),“Durox blockworks system“;London,TarmacTopblock

The construction method of using conventional bricks has been revolutionized by the

development and usage of interlocking concrete masonry units (CMU) and lightweight

concrete blocks. The tedious and time-consuming traditional brick-laying tasks are

greatly simplified by the usage of these effective alternative solutions.

INDUSTRIALIZED BUILDING

SYSTEM (IBS) IN MALAYSIA

STEEL FRAMING SYSTEM

BLOCKWORK SYSTEM

STEEL FORMWORK SYSTEM

PRECAST CONCRETE FRAMING SYSTEM

PREFABRICAED TIMBER FRAMING SYSTEM

Figure 2.24- Types of Industrialized Building System (IBS) in Malaysia

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2.3 CHARACTERISTIC OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to Thanon et al (2003), there are essential characteristics underlining the

successful implementation of industrialized building system (IBS) in general. Each of

them is briefly discussed below.

2.3.1 Closed System

A closed system can be classified into categories, namely production on the client’s

design and production based on the precaster’s design. The first category is designed to

meet a spatial requirement of the client 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 the precaster’s design

includes designing and producing a uniform type of building or a group of building

variants, which can be produced with common assortments of components. Such

buildings include school parking garage, gas station and low cost housing. Nevertheless

these types of building arrangements 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 that incur due to

the specific design.

b) The architectural design observes large repetitive elements and

standardization. In respect to this, a novel prefabrication system can

overcome the requirement of many standardized elements by

automating the design and production process.

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

schools, so that a mass production can be obtained.

c) There is an intensive marketing strategy by precaster to enlighten the

clients and designer about the potential benefit of the system in term of

economics and non- economic aspects.

2.3.2 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 allows the precaster to

produce a limited number of elements with a predetermined range of product and at the

same time maintaining architectural aesthetic value.

Despite the many advantages inherent in an open system, its adoption experience 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.

2.3.3 Modular Coordination

Modular co-ordination is a co-coordinated unified system of 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 coordination 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

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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 module0 and by limiting the dimension of building

components to a recommended preferred sizes (Warszawski, 1999).

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

their interchangeability 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 coordination for building components 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 to adopt, its

application involves a great degree of coordination and adjustment in the manufacturing

process and the interfacing aspects of component.

2.3.4 Standardization and Tolerances

In order to accomplish the requirement of modular co-ordination, all components need

to be standardized for production. Such standardization 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 consideration is within the permitted limits (Trikha, 1999).

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

standardized. Then the production process, machinery, and workers’ training can be

best absorbed to the particular characteristic of the product.

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2.3.5 Mass Production

The investment in equipment, human resources, and facilities associated with

industrialization 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.

2.3.6 Specialization

Large production output and standardization of precast elements allow a high degree of

labour specialization with the production process. The process can be subdivided into a

large number of small homogeneous tasks. In such working conditions, workers are

exposed to their work repetitiously with higher productivity level (Warszawski, 1999).

2.3.7 Good Organization

High production volume, specialization of work, and centralization of production

requires an efficient and experienced organization capable of a high level of planning,

organizing, coordination and control function with respect to production and

distribution of the products (Warszawski, 1999).

2.3.8 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).

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2.3.9 Production Facility

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

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 high demand for the products. On the other hand, a temporary casting yard

or factory can be established at the project site in order to minimize the transportation

cost.

2.3.10 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 cost. The

transportation of large panel system is also subject to the country’s road department

requirement. This limitation must be taken into consideration when adopting a

prefabrication system.

2.3.11 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).

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TRANSPORTATION MODULAR COORDINATION

ESSENTIAL CHARACTERISTIC

OF SUCCESSFUL IMPLEMENTATION

OF IBS

GOOD

ORGANIZATION EQUIPMENT AT SITE

OPEN SYSTEM

INTEGRATION

CLOSED SYSTEM

MASS PRODUCTION

SPECIALIZATION

PRODUCTION FACILITY

STANDARDIZATION & TOLERANCE

Figure 2.25 – Essential Characteristic of IBS

2.4 BENEFITS OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to CIDB (2003), Industrialized Building System (IBS) has the following

benefits when compared to the conventional construction method.

i. Low site workers requirement due to simplified construction methods.

ii. Quality-controlled and highly aesthetic end products through the process of

controlled pre-fabrication and simplified installations.

iii. Reduction of construction materials at sites through usage of pre-fabricated

components.

iv. Reduction of elimination of conventional timber formworks: replaced by

prefabricated components and alternative moulds with multiple-usage capability.

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v. Reduction or elimination of props due to the absence of conventional timber

props and usage of prefabricated components.

vi. Reduction of construction waste with the usage of the standardized components

and less in-site works.

vii. Cleaner sites due to lesser construction waste.

viii. Safer construction sits due to the reduction of site workers, materials and

construction waste.

ix. Faster completion of construction projects due to the usage of standardized pre-

fabricated components and simplified installation processes.

x. Cheaper total construction costs; made possible due to all of the above.

2.5 SHORTCOMINGS OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to Thanon et al (2003), the adoption of IBS is not without its limitations and

shortcomings, these shortcomings of an IBS system are as discussed below:

i. An IBS system can only be acceptable to practitioners if its major advantages

are valuable compared to the conventional system. However, as to date, there is

inadequate corroborative scientific research undertaken to substantiate the

benefits of IBS system. It is therefore, arguable that the implementation of IBS

is particularly hindered by lack of scientific information in relation to the

Malaysian construction industry,

ii. Standardization of building elements faces resistance from the construction

industry due to aesthetic reservation and economic reason. One good example of

this is when a 300mm thick modular standardized floor slab has to be used

although a 260mm thick floor slab can achieve the similar structural

performance. This results in wastage of material.

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iii. The selection of a new IBS has been hindered by lack of assessment criteria set

by the approving authorities. This phenomenon has been even more detrimental

to the development of an indigenous IBS. With such reason, absence of the

assessment criteria has been identified as the most important inhibitor to the

introduction of IBS in construction industry.

iv. A general decline in demand and volatility of the building market for large

public housing projects in most developed countries make an investment in IBS

more risky compared with the conventional labour intensive methods. This

reason is substantiated by a cheap imported labour in several European countries

(Warszawski, 1999).

v. The industrialization of building process which emphasizes on the repetitiveness

and standardization cause monotonous “barrack like” complexes that very often

turns into dilapidated slums within several years. This shortcoming is further

reinforced by production defects in building components which are quite

frequent in the initial stages of prefabrication. Such defects resulting from lack

of technical expertise and poor quality control cause aesthetic and functional

faults, such as cracks, blemishes, moisture penetration, and poor thermal

insulation in completed building (Warszawski,1999).

vi. Prefabricated elements are considered inflexible with respect to changes which

may be required over its life span. This may occur when small span room size

prefabrication is used (Warszawski, 1999).

vii. At university level, students are less exposed to technology, organization and

design of industrialized building system. The academic curriculum seldom

includes courses that incorporate a thorough and methodological manner, the

potential and the limitations associated with industrialization in building. As

consequences, there is a natural tendency among practitioners to choose

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conventional methods perhaps with occasional utilization of single prefabricated

elements (Warszawski, 1999).

viii. The weakness of existing industrialized building system is still in its

cumbersome connections and jointing methods which are very sensitive to errors

and sloppy work. Also, standardization of joint and connection detail may delay

the evolution of new technology.

ix. An adaptation of standardization requires a tremendous education and training

effort. Hence, it requires an initial immense of investment cost. This is cited as

one of the greater hindrances to the use of modular coordination in IBS.

2.6 GROWTH OF THE USAGE OF IBS IN MALAYSIA CONSTRUCTION

INDUSTRY

According to CIDB (2005), since the resolution made during the Colloquium on

Industrialized Construction system in 1998, CIDB Malaysia as the lead secretariat for

the construction development in Malaysia has been concentrating in doing promotions

and training on IBS and it has since shown some positive results. It was concluded in a

report that productivity growth in the industry was attributed by greater efforts made in

promoting IBS in order to increase productivity and quality of output (NPC, 2004). As

highlighted in Table 2.1, percentage of projects using at least a form of IBS had

increased steadily from 1998 (Sharul, 2003).

1998 1999 2000 2001 2002 2003

Productivity growth for construction (%)

-12.71

-4.91

2.33

0.39

2.51

2.55

Percentage of completed projects using at least one form of IBS (%)

21

24

30

34

42

-

Table 2.1-Comparison between Productivity Growth and Usage of IBS in Malaysian

Construction Industry

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While the efforts seem to be successful, there is still a lot of room for improvement

(Sharul, 2003). He added that a greater coordination of the whole industry is needed for

a greater success in the promoting IBS. In coordinating the industry towards greater

usage of IBS in construction, CIDB in 2003 has formulated it master plan with the

guidance from the IBS steering committee that are represented by the stakeholders of

the industry (Sharul, 2006). According to him, the master plan fully known as

“Industrialized Building System (IBS) Roadmap 2003-2010, is based on the Five (5) M-

Strategy namely (Manpower, Material-Components-Machines, Management-Processes-

Methods, Monetary and Marketing) with the target of having an industrialized

construction industry by the year 2010 .

According to CIDB (2003), the main items in the Master plan are as follow:

i. To have a labour policy that gradually reduces percentage of foreign workers

from the current 75% to 25% in 2007 and 15% in 2010.

ii. To enforce minimum IBS content for private developers from 2008.

iii. To begin specialize installer programme for IBS registration code from 2004.

iv. To enforce Modular coordination through amendments to the Uniform Building

By-Laws (UBBL) from 2004.

v. To develop a series of catalogue for the building components (Precast concrete

standard components by 2004).

vi. To develop an IBS Verification Scheme as a quality assurance programme for

IBS components by 2005.

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vii. To enforce utilization of IBS in government building projects-from 30%

gradually increased to 50% in 2006 and 70% in 2008; commencing from

inception stage of public project.

viii. To provide tax incentives for manufacturers of IBS components from 2005.

ix. To start Bumiputera manufacturers and specialized contractors (installer)

training and financial aid programmes by 2004, and

x. To offer CIDB levy exemption for IBS residential buildings from 2004.

In order to provide the kick-start element of the master plan, initial boost from the

government was needed (CIDB, 2005). According to CIDB (2005), through the 2005

Budget Speech; the government has addressed a number of initiatives to cater for the

demand side of the implementation of IBS and strengthen the industrialization agenda

in construction as illustrated in Figure 2.3.

Third Announcement

All contractors who built housing projects using more than 50% IBS content

would be given incentives in the form of full exemption of CIDB levy.

Second Announcement

The government requires that all government buildings to be constructed

using a minimum of 50% IBS content.

First Announcement The government has pledged to construct 100,000 units of affordable houses

using IBS

Figure 2.26- The “2005 Budget Speech” on IBS on 10th September 2004

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According to Sharul (2006), the directive of 50% IBS content for government building

project was in fact made one year ahead of the IBS Roadmap target; showing full

commitment by the government in supporting the industrialization agenda. In the 2006

Speech Budget, the government has pledged to continue supporting IBS usage as well

as ensuring all IBS components to meet the Modular Coordination (MC) standard MS

1064 which a guide line to coordinating dimension and space of which buildings and

components are dimensionalised and positioned in basic units or modules (CIDB,

2005).

According to CIDB (2005), the implementation of IBS would increase once the new

projects under the Ninth Malaysian Plan (9MP) being awarded starting from 2006.

Besides, Sharul (2006) mentioned that the IBS components would contribute to greater

demand in the future whereby the need of renewable energy in building components to

be supplied as the wake of the escalating oil prices. According to him, a greater demand

of IBS components in public projects is expected to be experienced by the increasing

IBS manufacturers in Malaysia. As stated in Table 2.2, there are currently 129

manufacturers of various IBS product in Malaysia (CIDB, 2005). IBS Product type Manufacturer

Precast concrete Frames/ Panels / Box & Precast Block 50

Steel Frames 27

System Formworks (steel ,etc) 24

Prefabricted Timber Frames 28

TOTAL 129

Table 2.2 – Number of IBS Manufacturers as of 17th October 2005

The demand of IBS in the future will contribute to the success of the industrialization

agenda of the government in construction sector; however the agenda should

incorporate the industry players; Builder, Developers, Architects, Engineers and

especially the Quantity Surveyor (Sharul, 2006).

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2.7 SUMMARY

Based on this chapter, the overview of the concept of industrializing construction

activities generally has been discussed. The discussion also included the revolution of

industrialization in the construction sector globally and specifically in Malaysia. In

addition to that, thorough study on the implementation of IBS in Malaysia has also been

conducted in term of the available types of IBS, its characteristic and growth of IBS.

Finally, the benefits and shortcoming of IBS also been elaborated.

The latter chapter will discuss on the project management during construction stage

generally and specifically to construction management aspects. Furthermore, factors

and components will be identified that may contribute to construction cost during

construction phase.

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