A

rticle

Industrialised Building System: Current Shortcomings And The Vital Role Of R&D
By Kamarul Anuar Mohamad Kamar, Ir. Dr. Zuhairi Abd. Hamid, Mohd Khairolden Ghani and Ahmad Hazim Rahim, Construction Research Institute of Malaysia 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.

BS is defined as a construction system in which components are manufactured in a factory, on or off site, positioned and assembled into structure with minimal additional site work (CIDB, 2003). Dietz, A.G.H (1971) earlier defined IBS as total integration of all subsystem and components into overall process fully utilizing industrialized production, transportation and assembly techniques. Lessing et al, (2005) defined IBS as an integrated manufacturing and construction process with well planned organization for efficient management, preparation and control over resources used, activities and results supported by the used of highly developed components. Trikha (1999) defined as a system in which concrete components prefabricated at site or in factory are assembly to form the structure with minimum in situ construction. IBS is also defined as a set of interrelated element that act together to enable the designated performance of the building (Warszawski, 1999). Parid Wardi (1997) defined IBS as a system which uses industrialised production techniques either in the production of components or assembly of the building or both. Esa and Nurudin (1998) asserted that IBS is a continuum beginning from utilizing craftsmen

for every aspect of construction to a system that make use of manufacturing production in order to minimize resource wastage and enhance value for end users. Junid (1986), identified IBS as a process by which components of a building are conceived, planned and fabricated, transported and erected at site. The system includes a balanced combination between software and hardware component. The software element include system design, which is a complex process of studying the requirement of the end user, market

analysis and the development of standardized components.

History of IBS in Malaysia

IBS began in early 1960s 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 the year 1964, the Government had launched pilot project on IBS to speed up the delivery time and

LRT station
62
2nd Quarter 2007

rticle

built affordable and quality houses. Nearly, 22.7 acres of land along Jalan Pekeliling was dedicated to the project comprising seven blocks of 17-storey flats (3,000 units of low-cost flat and 40 shop lot). This project was undertaken by Gammon/ Larsen Nielsen using the Danish System of large panels in a pre-fabricated system. In 1965, the Government of Malaysia launched a second project, a six block of 17-storey flats and three blocks of 18-storey flats at Jalan Rifle Range. The project was awarded to Hochtief/ Chee Seng using French Estoit System (Din, 1984). Between 1981 and 1993, PKNS a state Government development agency acquired pre-cast concrete technology from Praton Haus International based in Germany to build low-cost houses and high cost bungalows in Selangor (National IBS Survey, 2003). Today in the Malaysian construction industry, the use of IBS as a method of construction is evolving. More local manufacturers have established themselves in the market. As a result pre-cast, steel frame and other IBS were used as hybrid construction methods to build national landmarks such as Bukit Jalil Sport Complex, LRT and Petronas Twin Tower. It was reported that at least 21 manufactures and suppliers of IBS are actively promoting their systems in Malaysia. IBS move to the next step of the development through the establishment of IBS Centre at Jalan Chan Sow Lin, Cheras, Kuala Lumpur. The obligation to implement IBS serves both to improve performance and quality in construction, as well as to minimize dependency on unskilled foreign labour in the construction market.

Bukit Jalil Sport Complex

Shortcomings of IBS
CIDB published the IBS Roadmap 20032010 which detailed the needs and requirements of Malaysian construction industry. This roadmap was endorsed by Cabinet on October 29, 2003. 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,

each beginning with M. They are Manpower, Materials, Management, Monetary, and Marketing. The inputs are then divided into elements and the activities to be implemented for each element were then identified and included into the time span of the Roadmap in order to achieve the mission within the stipulated timeframe. The content of this roadmap is focused towards achieving the industrialisation of the construction sector and the longer term objective of Open Building Systems concept. It has been five years since the launching of the Roadmap and more than half-way the target of industrialising construction. It is pertinent to examine the progress and how close we are to the completion of the mission. More importantly, it is imperative to evaluate whether the implementation of the roadmap has met the market response to the IBS programme. Most policy issues have been resolved and implemented, while all relevant documents required to support the programme have been developed. In particular, activities under the charge of CIDB are all meeting their deadlines. Notwithstanding these achievements,

a number of implementation snags were identified as being potential hurdles to the implementation of the Roadmap. These include the following which have been identified by IBS Steering Committee:

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 programme, Vendor development programme, Readiness of designers and consultant practices, quality control, production of standard components in the field of IBS.

Realising the implementation of IBS is still to make headway, CIDB through Construction Research Institute of Malaysia (CREAM) has taken the initiative to conduct three workshops for the industr y. After lengthy deliberation with stakeholders, it was concluded that the factors contributing to the delay of IBS implementation are as follows:

63
2nd Quarter 2007

rticle

It is not popular choice among design consultants Lack of knowledge among designers The need for mindset change with proper education Costing chicken and egg problem Private sector adoption Proprietary systems make it hard to be adopted by designers Poor quality products Joints are not standardised making it hard to design as the designs are fixed by a particular manufacturer Insufficient push factor Lack of technical know-how e.g. structure Volume and economies of scale The monopoly of big boys, limiting opportunities to Bumiputra contractors. Require

appropriate training for Bumiputra contractors Low off-site manufacturing of construc tion components to guarantee quality, mechanization and standardization To consider IBS design that promote energy conservation Sustainability of construction industry, Government to lead during downturn Require on-site specialised skills for assembly and erection of components Lack of special equipment and machinery which hamper work. Require more local R&D, support services, technologies and testing labs Insufficient capacity building for contractors to secure project in construction (G1-G7)

Below 10% IBS construction involvement by Bumiputra contractors Mismatch between readiness of industries and IBS targets by CIDB The cost depends on volume and types of projects Ear thquake resistant design pertaining to IBS components (e.g joint system, seismic performance and design guidelines) Earthquake protection of IBS buildings (base isolation and rubber damping systems) No standard joint developed for building components

The Way Forward

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, CREAMs R&D output will geared towards industrys application and requirements. 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. CREAM shall take the following actions as a prerequisite 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,

Petronas Twin Tower

64
2nd Quarter 2007

rticle

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,

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.

Acknowledgement
We would like to thank Malaysian IBS Steering Committee Session 2003-2005 and IBS Centre for their support and assistance.

References
CIDB (2003), IBS Roadmap 2003-2010, CIDB publication CIDB (2003), Construction Industry Master Plan 2006-2015, CIDB publication CREAM (2007), Strategic Management of R&D in IBS unpublished documentation by CREAM CREAM (2007), Workshop on aligning R&D themes and titles to the requirement of construction industry unpublished report by CREAM CIDB, (2003), National IBS Survey, 2003, CIDB publication Dietz, A.G.H (1971) as stated in Jaafar, S., et al (2003), Global Trends in Research, Development and Construction, proceeding of The International conference On Industrilised Building System (IBS 2003), CIDB Din, (1984), Industrilised building and its application in Malaysia, proceeding on Seminar on Prefabrication Building Construction. Esa and Nurudin (1998), Policy on industrilised building system, report on qollocium on industrilised construction system, Kuala Lumpur. Hervas et. al (2007), as stated in Kazi, S., (2007), Open Building Manufacturing Core Concept and Industrial Requirement, Manubuild Consortium. Junid, S., (1986), Industrilised Building System. Proceeding of UNESCO/FEISEAP regional workshop. Lessing et al, (2005), as stated in Kazi, S., (2007), Open Building Manufacturing Core Concept and Industrial Requirement, Manubuild Consortium. Parid Wardi (1997), as stated in Jaafar, S., et al (2003), Global Trends in Research, Development and Construction, proceeding of The International conference On Industrilised Building System (IBS 2003), CIDB Thanoon et al, (2003), An assessment of the industrilised building system in Malaysia, Proceeding on IBS Seminar, UPM, Malaysia Trikha (1999), Industrilised building system: prospect in Malaysia. Proceeding of World Engineering Congress, Kuala Lumpur. Warszawski, (1999), Industrilised and automated building system, Technion-Israel Institute of Technology, E & FN Spon

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.

65
2nd Quarter 2007