barriers in the implementation of industrialised building...
TRANSCRIPT
BARRIERS IN THE IMPLEMENTATION OF INDUSTRIALISED BUILDING
SYSTEM IN MALAYSIAN CONSTRUCTION INDUSTRY
KONG XI HAW
A report submitted in partial fulfilment of the
partial requirement for the award of the degree of
Master of Science (Construction Management)
Faculty of Civil Engineering
Universiti Teknologi Malaysia
June 2009
iii
to my family and friends
iv
ACKNOWLEDGEMENT
This paper is successfully completed with the assistance and support of my
honourable project supervisor, Professor Dr. Muhd. Zaimi Abd. Majid.
I would like to express my utmost thankfulness to my supervisor, Professor
Dr. Muhd. Zaimi Abd. Majid for his credible comments and advices starting from the
preparation of research, literature reviews, questionnaires survey until the drafting
and writing part of this research report. His guidance throughout the whole two
semesters is the principle which leads me in successfully finalising this research
report. Also, Professor Dr. Muhd. Zaimi encouragement is no less important which
make me full of enthusiasm all along the way. His ideas are always an inspiration for
me to move further.
Secondly, I would like to express our thanks to the questionnaires‟
respondents for their willingness to provide constructive views about IBS and it is
hoped that they will accept this anonymous recognition. I am also grateful to the
people who help to distribute these questionnaires. Their patience and support during
the entire process of collecting the primary sources indeed is a great help to me.
Finally, I would like to acknowledge our debt to all those who have helped with the
writing of this research report.
KONG XI HAW
29th June 2009
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ABSTRACT
Industrialised Building System (IBS) were introduced to Malaysia to solve
issues associated with dependencies of foreign workers, raising demand of affordable
accommodations and improving image, quality and productivity of construction
industry. This research is to highlights the current development of IBS in Malaysian
construction industry and potential challenges related to the implementation of IBS.
The objectives of the research are to identify the readiness of adapting IBS;
determine the barriers in the implementation of IBS; and identify ways to enhance it.
Questionnaires survey was conducted in order to achieve the objectives. The
respondents consisted of architects, contractors, developers, consultants and quantity
surveyors. The data were tabulated using Microsoft Excel and then analysed using
average index. In conclusion, the barriers of IBS implementation in Malaysia has
been identified and discussed. According to this research, technical limitation, lack
of standardisation and price of IBS are the main barriers in IBS implementation in
Malaysia.
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ABSTRAK
Sistem Bangunan Berindustri (IBS) diperkenalkan di Malaysia untuk
mengatasi isu-isu yang berkenaan dengan masalah yang berkaitan buruh asing,
pemintaan yang kian meningkat terhadap perumahan dan juga untuk meningkatkan
imej, kualiti serta produktiviti bagi seluruh industri pembinaan. Kajian ini adalah
untuk menitikberatkan pengembangan Sistem Bangunan Berindustri dalam industri
pembinaan Malaysia dan juga cabaran yang berkaitan dengan perlaksanaan Sistem
Bangunan Berindustri. Objektif bagi kajian ini adalah untuk mengenalpasti
penyediaan industri pembinaan untuk menerima Sistem Bangunan Berindustri;
menentukan halangan dalam perlaksanaan Sistem Bangunan Berindustri; dan
mengenalpasti cara-cara untuk mengatasi situasi tersebut. Tinjauan dengan soal
selidik dilakukan untuk mencapai objektif yang ditetapkan. Responden-responden
terdiri daripada arkitek, kontraktor, pemaju, perunding dan juruukur. Data yang
dikumpul dianalisis dengan menggunakan indeks purata dengan bantuan aplikasi
Microsoft Excel. Dengan keputusan yang diperolehi, halangan daripada
menglaksanakan Sistem Bangunan Berindustri telah dikenalpasti dan dibincangkan.
Menurut kajian ini, sokongan teknikal yang terhad, kekurangan keselarasan dalam
piawai yang berkenaan dengan Sistem Bangunan Berindustri dan faktor harga adalah
halangan utama dalam perlaksanaan Sistem Bangunan Berindustri di Malaysia.
vii
TABLE OF CONTENTS
CHAPTER TITLE PAGE
DECLARATION ii
DEDICATION iii
ACKNOWLEDGEMENT iv
ABSTRACT v
ABSTRAK iv
TABLE OF CONTENTS vii
LIST OF TABLES xi
LIST OF FIGURES xiii
LIST OF ABBREVIATIONS xv
LIST OF APPENDICES xvi
1 INTRODUCTION 1
1.1 Introduction 1
1.2 Background 2
1.3 Problem Statement 4
1.4 Aim and Objectives of the Study 4
1.4 Scope of the Study and Limitations 5
1.5 Significance of the study 6
1.6 Research Questions 6
1.7 Research Methodology 7
1.8 Structure of Report 8
2 LITERATURE REVIEW 9
2.1 Definitions 9
2.2 Classification of Building System 10
viii
2.3 Classification of IBS 12
2.3.1 Precast Concrete Systems 12
2.3.2 Steel Formwork System 15
2.3.3 Steel-framed building and Roof Trusses 16
2.3.4 Prefabricated Timber Framing System 17
2.3.5 Block Work System 18
2.4 Essential Characteristics of IBS 19
2.4.1 Closed System 19
2.4.2 Open Building System (OBS) 20
2.4.3 Modular Coordination 21
2.4.4 Standardisation and Tolerances 21
2.4.5 Mass Production 22
2.4.6 Specialisation 22
2.4.7 Good Organisation 22
2.4.8 Integration, Planning and Control of the
Processes 23
2.4.9 Production Facility 23
2.4.10 Transportation 24
2.4.11 Equipment at Site 24
2.5 The Benefits of IBS 24
2.6 Shortcomings of IBS 25
2.7 IBS in another point of view 27
2.8 Experiences and Implementation of IBS in
Other Countries 28
2.8.1 Germany 28
2.8.2 Netherlands 29
2.8.3 United Kingdom 31
2.8.4 United States of America 32
2.8.5 Japan 34
2.8.6 Singapore 34
2.8.7 Thailand 35
2.8.8 Denmark 39
2.8.9 History of IBS in Malaysia 39
2.9 Impediments to Progress of IBS in Malaysia 42
ix
2.9.1 Development of IBS in Malaysia 43
2.10 IBS Roadmap 2003 -2010 48
2.10.1 IBS Roadmap Mid-Term Report 51
2.11 Barriers to the Implementation of IBS 52
2.12 Construction Industry Master Plan (CIMP)
2006-2015 56
2.13 Summary 57
3 RESEARCH METHODOLOGY 59
3.1 Introduction 59
3.2 Research Methodology 59
3.3 Literature Review 61
3.4 Questionnaire 61
3.4.1 Sampling of Data 61
3.4.2 The Design of Questionnaire 62
3.5 Methods of Analysis 64
3.5.1 Average Index 64
3.5.2 Frequency Analysis 65
3.5.3 Rank 65
3.5.4 Standard Deviation 65
3.5.5 Comments 65
3.6 Summary of Chapter 66
4 ANALYSIS AND DISCUSSION 67
4.1 Introduction 67
4.2 Distribution and Return of the Questionnaire 67
4.3 Question Structure 68
4.4 Respondent information 69
4.4.1 Respondent Distribution 69
4.4.2 Respondent Position 70
4.4.3 Respondent Experience in Construction
Industry 70
4.5 Readiness of adapting IBS in construction
projects 71
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4.5.1 Experience of IBS in Construction
Industry 71
4.5.1.1 Knowledge in IBS 72
4.5.1.2 Experiences in IBS 73
4.6 Respondent experience with types of IBS 73
4.7 Readiness of using IBS in building projects 76
4.8 Factors affecting the development of IBS 77
4.9 Barriers of adapting IBS in construction
industry 77
4.10 Ways to enhance implementation of IBS 81
4.11 Introduction 82
4.11.1 Reliance on manpower 83
4.11.2 Avoid mismatch between the roadmap
and readiness among contractors and
designers 83
4.11.3 Barriers of implementing IBS to various
parties in construction 84
4.11.4 The Ways of Implementing IBS 84
5 CONCLUSIONS AND RECOMMENDATIONS 85
5.1 Conclusions 85
5.1.1 Objective 1: To identify readiness of
contractors and designers to adapt IBS in
their construction projects 85
5.1.2 Objective 2: To determine barriers in the
implementation of IBS in Malaysian
construction industry 86
5.2.3 Objective 3: To identify ways to enhance
the implementation of IBS in construction
industry 86
5.2 Recommendations 86
REFERENCES 88
APPENDIX 92
xi
LIST OF TABLES
TABLE NO. TITLE PAGE
2.1 Building system classification according to
relative weight of component (Majzub, 1977) 11
2.2 Registered IBS Contractor (Active) in Malaysia
by IBS Grade (B01, B02, B12, B15 and B19
(2007) 47
2.3 Registered IBS Contractor (Active) in Malaysia
by CIDB Grade (2007) 47
2.4 Registered IBS Manufacturer and IBS Products
available in Malaysia 48
2.5 Expected Target of CIMP Strategic Thrust 5 and
Strategic Thrust 6 by year 2015 57
4.1 Respondent Experience with IBS 72
4.2 Respondent experience with types of IBS 74
4.3 Readiness of using IBS in building projects 76
4.4 Factors affecting the development of IBS 78
4.5 Barriers in the implementation of IBS in
construction industry 79
4.6 Barriers in the implementation of IBS in
construction industry (in categories) 80
4.7 Ways to enhance implementation of IBS 82
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LIST OF FIGURES
FIGURE NO. TITLE PAGE
1.1 Research flow chart 7
2.1 Types of building system according to Badir-
Razali classification in Malaysia (Badir, 1998) 12
2.2 Precast concrete framing, panel and box systems
(NFPA pictures, 2004) 13
2.3 Precast concrete wall system (NFPA pictures,
2004) 14
2.4 Building with precast concrete slab (Tekla
pictures) 15
2.5 PERI TRIO Steel Formwork System (PERI
Formwork System Inc. pictures) 16
2.6 Typical project using steel framing system
(Sufian, 2009) 17
2.7 Typical project using timber forming system
(Sufian, 2009) 17
2.8 Typical project using block work system
(Sufian, 2009) 18
2.9 Examples of innovative IBS components
produced in Singapore 36
2.10 The application of PLP in construction industry
of Thailand 38
2.11 The sources of IBS in Malaysia according to the
origin of countries (Badir et al, 2002) 44
2.12 IBS 5M Component Elements (IBS Roadmap
2003) 49
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3.1 Research flow chart 60
4.1 Return Percentage of Questionnaire by the
Respondents 68
4.2 Collected returns of usable questionnaires 69
4.3 Current Position of Respondents in Construction
Industry 70
4.4 Respondent Experience in Construction
Industry 71
4.5 Construction Company Experience in
Construction Industry 71
4.6 Knowledge of IBS according to their profession 73
4.7 Experience analysis in at least a type of IBS 75
4.8 Barriers in the implementation of IBS in
construction industry 81
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LIST OF ABBREVIATIONS
3D - dirty, difficult, dangerous
BAIHP - The Building America Industrialized Housing Partnership
BS - British Standards
CIDB - Construction Industry Development Board
CIMP - Construction Industry Master Plan
CREAM - Construction Research Institute of Malaysia
dB - Decibel
DIN - the German Institute for Standardization
GDP - gross domestic product
HDB - The Housing and Development Board
IBS - Industrialised Building Systems
ICT - Information, Communication and Technology
JKR - Jabatan Kerja Raya
KPIs - key performance indicators
LRT - Lightweight Railway Train
MC - Modular coordination
MIGHT - Malaysian Industry-Government Group for High Technology
MS - Malaysian Standards
NFPA - National Fire Protection Association
NHA - National Housing Authority
OBS - Open Building System
PCA - Portland Cement Association
REHDA - Real Estate and Housing Developers' Association Malaysia
PKNS - Perbadanan Kemajuan Negeri Selangor
PLPC - Precast Large Panel Construction
PTC - Prefabrication Technology Centre
UBBL - Uniform Building By Law
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LIST OF APPENDIX
APPENDIX TITLE PAGE
1 Technical Paper 92
CHAPTER 1
INTRODUCTION
1.1 Introduction
Malaysia is well known for its forward looking policies and strategies in the
quest for global participation in all facets of industry. Being a global player in
construction requires serious efforts towards adopting new systems and technologies
par excellence with other developed and developing nations. The success of these
efforts will enable us to penetrate the global market and export our professional and
construction expertise while improving our own local development and management.
The construction industry plays a crucial role in the Government‟s efforts to
stimulate domestic economic activities and enhance growth. It is therefore important
for the sector to continuously undertake measures to increase efficiency, quality and
productivity. Towards this end, the use of the Industrialised Building Systems (IBS)
is the right step in realising this objective.
IBS promises elevated levels of expertise throughout the industry, from
manufacturers, installers, engineers, planners, designers and developers. The benefits
of IBS are numerous and far reaching. Reduced construction time, better site
management, reduced wastage are but a few of these benefits, that will ultimately
produce better products for the population. Undoubtedly, with better productivity,
quality and safety, IBS will contribute towards a better construction industry, as well
as enhance the global competitiveness of Malaysian builders.
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The author is a postgraduate student from Univerisiti Teknologi Malaysia and
has chosen barriers in current development of IBS as the area for the research. This
research developed a good level of understanding on the barriers in the
implementation of IBS in Malaysian construction industry.
1.2 Background
The construction industry constitutes an important element of Malaysian
economy. Although it account for only 2.8 percent of the gross domestic product
(GDP) in fourth quarter of 2008, the industry is crucial to national development as it
has the direct effects to the economy of the country. The construction industry also
provides job opportunities for approximately 800,000 people (CIMP 2006-2015).
According to Wang (1987), the construction industry can serve as a barometer
indicating the nation‟s economic conditions. Active construction activities generally
show that the nation‟s economy is booming and progressing well, and whereas
sluggish construction activities show that the country‟s economy condition is under
depression.
Based on the report by CIDB (2003), it also underlines the contributions from
the construction sector are more than just economic; where the products of
construction whether directly or indirectly through provision of superior
infrastructure and buildings has contributed extensively towards the creation of
wealth and quality of life of the population. The activities generated from the
construction activities will in turn generate the productivity of other industries,
resulting in a well-balance economy in Malaysia.
Construction industry basically consists of various processes, involves many
parties and different stages of work. It involves the participation of various parties
from various sectors in order to ensure the efficiency of the construction work carried
out. The efficiency and success of construction development and activities depends
heavily on the quality of managerial and organizational performance plus the
effective co-ordination through good teamwork from the different parties. It is
3
therefore obvious that the development of the construction industry can only be
achieved if every team members play effective roles in their work.
Nevertheless, the state of the local construction industry is not in line with
future development of Malaysia. The challenges often occur in the area of
productivity, efficiency of work and quality of work. Currently, the construction
industry is still using labour intensive and low technology methods of construction.
The intensive use of foreign unskilled workers and low technology equipment and
out-of-dated construction methods, eventually caused low productivity and efficiency
of work at construction site. As a result this has lead to unproductive practices and
initially contributes to the later delivery of work.
According to Ismail (2001), 800,000 units of houses has been planned and
out of that figure, 585,000 units or 73.1 percent were planned for low and medium
cost houses in the 7th Malaysia Plan. The disappointing fact is that only 20 percent
of completed houses were reported throughout the nation despite numerous
incentives and promotions to encourage developers to venture into such housing
category.
Waleed et al. (2003) reported that the announcement of the 8th Malaysia Plan
with the planning of 600,000 to 800,000 low and medium houses throughout the
nation. This is indeed welcoming news to the population of Malaysia especially to
the middle and low income groups. However, it is undoubtedly an uphill task to
accomplish such target with the current conventional building system currently
practiced widely in the Malaysian construction industry.
Therefore, the challenge the Industrialised Building System (IBS) is to create
a promising environment with the promise of improving productivity rate, lowering
construction costs and meeting the growing demand for affordable housing. In other
word, the awareness of current trends and latest construction technology and
innovation is essential in order to survive in the competitive market.
4
1.3 Problem Statement
The main problem in the construction industry is because of dependency on
foreign worker in Malaysia (IBS Roadmap 2003-2010). The country is in a difficult
situation where most of the foreign workers are usually unskilled labour dominates in
the construction industry. This lead to other problems such low quality works,
delays, wastages, social problems, diseases and etc. This discourage local workforce
is to join the industry because of cheap foreign labour sources. Low awareness in
occupational safety and health has created a dirty, difficult, dangerous (3D) image to
the construction industry. However, the dependency on foreign workers by the
Malaysian construction industry could be reduced by using industrialised building
systems (IBS). This is so because the prefabricated IBS components are
mechanically installed using cranes at sites using only a minimal number of
manpower. Besides requiring minimal labour, IBS offer better quality, increased
productivity and faster completion; less wastage with safer and cleaner construction
sites. Through IBS, components are prefabricated off-site, leaving the construction
sites tidier and cleaner.
Despite all the advantages and support from the government, early effort to
promote usage of IBS in Malaysian construction industry is still very low compared
to conventional methods. Although the members of the industry are open to the idea,
a major portion of the industry stakeholders are indifferent. This is probably due to
resistance towards change and insufficient information to support feasibility of
change. Local contractors are reluctant to switch to the usage of IBS because they are
at ease with the availability and relatively low cost of sourcing for unskilled foreign
labour. The adoption in Malaysia is more towards client-driven rather than consumer
driven as compared to developed countries.
1.4 Aim and Objectives of the Study
This aim of the research is to investigate and research for barriers in the
implementation of industrialised building system in Malaysian construction industry.
5
Specifically, to achieve to aim of this study, this research has the following
objectives:
1. To identify readiness of contractors and designers to adapt IBS in their
construction projects;
2. To determine barriers in implementation of IBS in Malaysian construction
industry; and
3. To identify ways to enhance the implementation of IBS in construction
industry
1.5 Scope of the Study and Limitations
In order to achieve the objectives of this study, the scope of the research only
focusing on the development of construction industry in Malaysia. Concentrating on
construction industry in Malaysia could give a clearer sight of view of the overall
development in local industry. Due to the extent that IBS mainly involved steel
structures and precast components, therefore the research are just restricted to the
building projects that uses IBS only.
By review on previous researches that focus on the similar area of study, some of
the barriers was highlighted and the input is obtained by questionnaires prepared based
on it. The respondents are mainly consisted of contractors, consultants, developers,
architects and quantity surveyors in Malaysia. This is to survey on the readiness of these
construction players to embrace IBS and identify barriers in implementation of IBS into
the construction industry.
The analyses are based on respondents‟ data from questionnaires only. The
analysis results do not represent the whole construction industry in Malaysia. However
the discussion is based on comparison of the analysed data and information from
literature studies. Conclusions were made according to objectives of the study.
6
1.6 Significance of the study
Currently the main challenges in Malaysia‟s construction industry is lack of
innovation and motivation as the workforce is aging and shrinking as progressively
fewer young enter the industry. If this phenomenon continues to go on, the industry
will swift to a very unhealthy condition, for example rely heavily on foreign workers,
lack of technology and modernisation in construction techniques. Hence, the
industrialisation of building construction method and the evolution of construction
technology are inevitable and plausible.
The first phase of successive implementation of IBS is the ability to find out
the barriers that hinders the development of IBS in Malaysia construction industry.
This is very important because if the barriers of implementation of IBS are identified,
it enables for finding out solutions by focusing effort to solve the problems.
1.6 Research Questions
It is essential to develop research questions in order to help on focus the area
research and the presentation of the report. Followings are some research questions
that arise when conducting the research:
What are the challenges and problems in construction industry?
What are the issues in current development of IBS in Malaysian construction
industry?
What are the barriers to the implementation of IBS in Malaysian construction
industry?
What type of information to be collected?
How to carry out the questionnaire?
Who are the respondents?
How to make use of the data collected?
7
1.7 Research Methodology
The research methodology has been carried out to fulfil the objectives of the
study which include the method of data collection such as documents study, case
study, preparation of questionnaires and data collection. The research procedures are
as shown in Figure 1.1.
Discussion with supervisor
Determine research topic
Identify research problem, issues and
objective of the studies
Objective 1:
To identify readiness of
contractors and
designers to adapt IBS in
their construction
projects
Objective 2:
To determine barriers
of the implementation
IBS in Malaysian
construction industry
Objective 3:
To identify ways to
enhance the
implementation of IBS
in construction industry
Literature review on previous researches,
thesis, journals and other publication
Prepare proposal paper for pre-project
presentation
Data collection
Distribute Questionnaires
References, Technical papers, journals
Data processing
Analysis and discussion
Conclusion and Recommendation
Figure 1.1: Research flow chart
8
1.8 Structure of Report
The research report is consists of five chapters where the content of each
chapter are summarized as follows:
Chapter 1 is the introduction part for the research report. It provides an
overall view of the whole report. Chapter 1 includes introduction, problem statement,
objective, and scope of the study, significance of the study, research questions,
research methodology and the structure of the report.
Chapter 2 is the literature review that based on findings from various
different sources of information such as journal, technical papers, books, research
paper etc. Chapter 2 includes definitions, classification of building system and IBS,
essential characteristic of IBS, benefits and shortcomings of IBS, experiences and
implementation of IBS in other countries, IBS in Malaysia, IBS Roadmap, barriers of
IBS in Malaysia and Construction Industry Master Plan (CIMP 2006-2015).
Chapter 3 describe in detail the research methodology which covered
literature review, questionnaires, preparation of the questionnaires, and method of
analysis.
Chapter 4 analysed the data using frequency analysis and average index for
the questionnaire survey. Chapter 4 also were discussed in detail the data analysed
and the findings were highlighted.
Chapter 5 highlights the findings and concludes the overall study on the
subject and evaluate whether the objective of the research are achieved.
Recommendations for further studies are also included in this chapter.
CHAPTER 2
LITERATURE REVIEW
2.1 Definitions
Until the present time there has been no single commonly-approved
definition of IBS. IBS can be different things to different industry players. However,
there are several definitions from other researchers that reflected the concept of IBS
which widely accepted by the construction industry.
In early literature, Dietz (1971) defined IBS as “a total integration of all
subsystem and components into overall process fully utilizing industrialised
production, transportation and assembly techniques”.
Meanwhile Junid (1986) delineated IBS as “process by which components of
building are conceived, planned and fabricated, transported and erected at site. The
system includes balance combination between software and hardware component.
The software element include system design, which is complex process of studying
the requirement of the 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”. The interpretation from Esa et al (1998) is that IBS as “continuum beginning
from utilising craftsmen for every aspect of construction to a system that make use of
manufacturing production in order to minimize resource wastage and enhance value
end users”.
10
Warszawski (1999) described IBS as “a set of interrelated element that act
together to enable the designated performance of the building”. At the same time
Trikha (1999) added that IBS is a “system in which concrete components
prefabricated at site or in factory are assembly to form the structure with minimum in
situ construction”.
Lessing et al (2005) explained 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”.
Rahman et al (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. The
components are manufactured offsite and once completed will be delivered to
construction sites for assembly and erection”.
Almost all the definition of IBS mentioned the prefabrication, off-site
production and mass production of building components as a main characteristic of
IBS. The scope of IBS focuses the construction of buildings rather than civil
structure or engineering projects. For the purpose of this research, IBS is best defined
according to CIDB Malaysia (2001) as “construction systems in which components
are manufactured in a factory, on or off site, positioned and assembled into a
structure with minimal additional in situ activities”.
2.2 Classification of Building System
In early stages, Majzub (1977) proposed a concept in classifying the building
system. He explains that the relative weight of the components should be used as a
basis for building classification which consists of frame system, panel system and
box system as presented in Table 2.1. The factor weight has significant impact on the
transportability of the components and also influence on the production method of
the components and the erection method on site. The main weakness of this
11
classification method is not suitable in Malaysia as it is found inadequate to
incorporate other building systems which flourish recently.
Table 2.1: Building system classification according to relative weight of component
(Majzub, 1977)
No. General
System
System Production Material
1 Frame system Light weight frame Wood, light gage metals
Medium light weight
frame
Metal, reinforced plastics,
laminated wood
Heavy weight frame Heavy steel, concrete
2 Panel system Light and medium
weight panel
Wood frame, metal frame
and composite material
Heavy weight panel
(factory produced)
Concrete
Heavy weight panel
(tilt up-produced on
site)
Concrete
3 Box system
(modules)
Medium weight box
(mobile)
Wood frame, light gage
metal, composite
Medium weight box
(sectional)
Wood frame, light gage
metal, composite
Heavy weight box
(factory produced)
Concrete
Heavy box (tunnel
produced on site)
Concrete
Later, Badir (1998) proposed there are four types of building system in
Malaysia with Badir-Razali classification. These building systems are namely
conventional system, cast in situ system, prefabricated system and the composite
building system is shown in Figure 2.1. Each building system represented by its
respective construction method which further characterised by its construction
technology, functional and geometry configuration.
Warszawski (1999) classified the building system into a few types which
depend on the particular interest of their users and producers. His classification uses
construction technology as a basis for classifying different building systems. In this
manner, four major groups can be distinguished such as system using timber, steel,
cast in situ concrete and precast concrete as their main structural as well as space
enclosing materials. These systems can be further classified according to geometrical
12
configurations of their main framing components that are the linear or skeleton
(beams and columns) system, planar or panel system and three dimensional or box
systems.
Figure 2.1: Types of building system according to Badir-Razali classification in
Malaysia (Badir, 1998)
2.3 Classification of IBS
In Malaysia, CIDB (2003) has classified IBS into five categories, which are
pre-cast concrete framing panel and box system, steel formwork systems, steel frame system,
timber frame system and block work system. IBS is a construction process that utilizes
techniques, products, components or building systems which involved prefabricated
components and on-site installation. From the structural classification, there are five
IBS main groups that are used in Malaysia as shown at following sub-section, which
mainly based on classification by CIDB with some modification to it.
2.3.1 Precast Concrete Systems
Precast Concrete Systems here is defined as any precast components that are
used in construction industry. This are included all type of precast concrete systems
Building System
Conventional column-beam-
slab frame system with timber and plywood in formwork
Cast in-situ system with steel or aluminium as
formwork
Table form
Tunnel form
Prefabricated system
Panel system
Block system
Frame system
Composite system
13
as defined at previous research, which shown in Figure 2.2 to 2.4 included as
follows:
a. Precast concrete framing, panel and box systems
b. Precast concrete wall system
c. Building with precast concrete slab
The precast concrete framed system as shown in Figure 2.2 is one of the
most popular forms of industrialised building system. The precast concrete framed
building consists of slab, beam and column component that are fabricated or
manufactured off-site using machine and formwork. The advantage of the system is
high degree of flexibility in term of larger clear distance between columns, as a result
longer span give bigger open space and greater freedom of areas.
Figure 2.2: Precast concrete framing, panel and box systems (NFPA pictures, 2004)
14
Precast concrete wall system consist a structural framework of the building
composed of pre-cast slab and load bearing wall. The load bearing walls and slabs
are manufactured off-site and transferred at site to be erected. The system is
preferred in simple and uncomplicated with a lesser degree of flexibility whereas the
removal of load bearing wall are restricted during the service life. With careful
design and good coordination between erectors and designers, the erection process
can be very fast with the number of wet trade in-site can be reduced significantly.
Figure 2.3: Precast concrete wall system (NFPA pictures, 2004)
Building with precast concrete slab is also known as hybrid construction as it
integrates precast concrete slabs and frames system. It consist a combination of
frames with precast concrete hollow core slab or precast planks. It become so
popular by the builders because the benefit of speed and high quality of precast
concrete slabs are combined with the benefit of economy, flexibility, monolithic
property and structural stability of framing system either with cast in situ concrete or
steel framing systems, which eventually gives a practical and efficient buildings.
15
Figure 2.4: Building with precast concrete slab (Tekla pictures)
2.3.2 Steel Formwork System
This system categorized as an IBS because the process of construction is
carried out using a systematic and mechanised method that is by using reusable steel
formwork panels. The system allows the rapid on-site placement of cast in situ
concrete to form beams, columns, slabs and walls. The system is better preferred for
the construction of walls instead of column and beam due to many repetitive of
similar wall components in wall frame buildings. Steel formwork components are
normally available in standard panel sizes and stiffened using built in stiffeners or tie
rods to resist lateral concrete pressure during concreting. It offers faster speed of
erection, comparatively lower cost and simplicity in equipment. It also provides good
accuracy and smooth internal finishing that eliminate the need of plastering. Example
of steel formwork system is as shown in Figure 2.5.
16
Figure 2.5: PERI TRIO Steel Formwork System (PERI Formwork System Inc.
pictures)
2.3.3 Steel-framed building and Roof Trusses
According to Sufian (2009), Steel is a strong and stiff material that suitable
for the construction and of reparative frame building with architectural detailing with
high flexibility in providing long-spanning structure. It normally used in for multi
story frames for tall and slander building and also for roof construction. The
advantages of using steel frame system as shown in Figure 2.6 are such as high
constructability and simplicity of construction as well as greater construction speed.
Just recently, steel roof trusses showed their capability in housing industries whereby
the cost became competitive as compared to timber roof trusses.
17
Figure 2.6: Typical project using steel framing system (Sufian, 2009)
2.3.4 Prefabricated Timber Framing System
In the early 1970s, single storey low cost terrace houses were mostly built out
of plain wooden framing and plank which sitting on those three feet high plastered
brickwork and taking advantages of the simple raft foundation due to the light weight
super structure. Figure 2.7 shows the houses construction for the low cost
development at rural area or remote town. Today this type of construction has been
classified as one of IBS.
Figure 2.7: Typical project using timber forming system (Sufian, 2009)
18
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.
However the usage of timber for IBS seems unrealistic in this era. In fact, the
perspective towards such implementation becomes worse when the cost of timber
rose recently. The main reason for choosing timber is just because of its flexibility,
conventional and economical reasons.
2.3.5 Block Work System
Referring to Sufian (2009), this system depends on modular dimension at the
design stage, which identical to Lego blocks to some extent. Furthermore, it applies
load bearing walls (as shown in Figure 2.8) by incorporating the columns and the
beams as integral part of the walls for all house types. The elements of block work
system include interlocking concrete masonry units 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. Depends on the
design, the amount that can be saved on a wall can range from between 10 percent to
30 percent with financial advantages such as up to 30 percent saving in wall
construction, faster in project completion, no beam and column, less foundation cost.
Figure 2.8: Typical project using block work system (Sufian, 2009)
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2.4 Essential Characteristics of IBS
Thanoon et al (2003) pointed out some of the essential characteristics which
reflect successful implementation of industrialised building system are briefly
discussed as follows:
2.4.1 Closed System
A closed system is classified into two categories, which are production based
on client‟s design and production based on pre-caster‟s design. The first category is
designed to meet a spatial requirement of the client‟s which is the space required for
different functions in the building as well as the specific architectural design. In such
design, the client‟s needs are paramount and the pre-caster is always tended to
produce specific component for the building.
On the other hand, Warszawski (1999) stated that the production based on
pre-caster‟s design includes designing and producing a uniform type of building or a
group of building components, which can be produced with common assortments of
component. Nevertheless these types of building arrangement can be justified
economically only when the following circumstances are observed.
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.
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d. There is an intensive marketing strategy by pre-caster to enlighten the clients
and designer the potential benefit of the system in term of economics and
noneconomic aspects.
2.4.2 Open Building System (OBS)
In view of the limitations inherent in the closed system, Open Building
System (OBS) allows greater flexibility of design and maximum coordination
between the designer and pre-caster has been proposed. Thanoon et al (2003) said
that this system allows the pre-caster to produce a limited number of elements with a
predetermined range of product and at the same time maintaining architectural
aesthetic value.
OBS enables openness in its structure supplier where everybody can bid to
produce lower price. In addition, the pre-caster and erectors will look for cooperation
models that will create win-win situation for both parties. Thanoon et al (2003)
added that OBS provides a high degree of design flexibility, which required a
maximum coordination between the designer and pre-caster.
In spite of many advantages inherent in OBS, its adoption experiences are
one of the major setbacks. 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.
However, OBS also allows the pre-caster to produce a limited number of
elements with pre-determined range of product and at the same time maintaining
architectural aesthetic value. Moreover, OBS is permitting hybrid application and
adaptable to standardisation and Modular Coordination (CIDB, 2003a).
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2.4.3 Modular Coordination
According to the definition proposed by Trikha (1999), modular coordination
is a coordinated integrated system for dimensioning spaces, components, and fitting.
This enables all elements fit together without cutting or extending even when the
components and fittings are manufactured by different suppliers.
Warszawski (1999) added that modular co-ordination creates a basis upon
which the variety of types and sizes of building components can be minimized.
Through a rationalised 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 of basic module and by limiting
the dimensions of building components to a recommended preferred size.
Warszawski (1999) further emphasised that modular co-ordination 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.
The modular co-ordination for building component apply the basic length
unit or module of M = 100 cm. 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.
2.4.4 Standardisation and Tolerances
All components need to be standardised for production to accomplish the
requirement of modular co-ordination. The standardisation of space and elements
required situational tolerances at different construction stages such as manufactured
22
tolerances, setting out tolerances and erection tolerances (Trikha, 1999). This is to
ensure that the combined tolerance obtained on statistical considerations is within the
permitted limits.
2.4.5 Mass Production
The investment in equipment, human resources, and facilities that related
with IBS can only be considered economical when there is large quantity of
production. Such volume can provides a distribution of the fixed investment charge
over a large number of product units without excessively increasing their ultimate
cost (CIDB Singapore, 1992).
2.4.6 Specialisation
Warszawski (1999) mentioned that large production output and
standardisation of precast elements enables a high degree of labour specialisation
with the production process. These processes can be divided into a large number of
small homogenous tasks. In such working condition, workers are exposed to their
work repetitiously that would pose higher productivity level.
2.4.7 Good Organisation
High production volume, specialisation of work, and centralisation of
production requires an efficient and experiences organisation (Warszawski, 1999). A
good organisation should capable of a high level of planning, organising,
coordinating and controlling function with respect to production and distribution of
IBS products.
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2.4.8 Integration, Planning and Control of the Processes
In order to obtain an optimal result, Warszawski (1999) pointed out that a
high degree of coordination must exist between various relevant parties such as
designer, manufacture, owner and contractor. This is archived trough integrated
system in which all these functions are performed under unified authority.
The design, manufacture, assembly and other related process requires a
coherent structure and management from the start to the end in order to reach the
goal and deliver a maximum value to the customers. A thorough planning of all
activities is required especially in the early stage of projects where extra attention
must be paid to design in aspect of architectural as well as engineering, planning and
preparation.
Lessing et al (1999) said that well prepared processes and complete design
when the production starts and the use of separately developed technical system,
supported by structured planning methods, the execution of the process will run
smooth and with a low amount of defect and errors. The strive is towards zero
defects and minimum amount of waste.
2.4.9 Production Facility
Peng (1986) pointed out that the initial capital investment for setting up a
permanent factory is depending on experience. Plant, equipment, skilled worker,
management resources need to be acquired before production can be commenced.
The investment can only be levelled if there is sufficient demand for the IBS
products. From the other point of view, temporary casting yard or factory can be
established at the project site in order to minimise the transportation costs.
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2.4.10 Transportation
Peng (1986) found out that casting of large-panel system can reduce labour
cost up to 30 percent. However, these cost savings are countered 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.
2.4.11 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.
2.5 The Benefits of IBS
Thanoon et al (2003) has summarized benefits of Industrialised building
system when compared to the conventional construction method as follows:
a. Prefabrication takes place at a centralised factory, thus reducing labour
requirement at site. Warszawski (1999) stated that this is true especially when
high degree of mechanisation involved.
b. Peng (1986) said IBS allows for faster construction time because casting of
precast element at factory and foundation work at site can occur
simultaneously. This can dramatically reduce construction time with good
coordination.
c. Warszawski (1999) said that IBS may allow flexibility in architectural design
in order to minimise the monotony of repetitive facades.
d. Bing et al (2001) commented that repetitive use of system formwork made up
steel, aluminium, etc and scaffolding provides considerable cost savings.
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e. According to Peng (1986), construction operation is not affected by adverse
weather condition because prefabricated component is done in a controlled
environment.
f. Zaini (2000) mentioned that IBS provides flexibility in the design of precast
element as well as in construction so that different systems may produce their
own unique prefabrication construction methods.
g. Din (1984) commented that IBS component is higher quality of components
through careful selection of materials, use of advanced technology and better
quality control.
2.6 Shortcomings of IBS
The adoption of IBS is not without its limitations. Below discuss the shortcoming of
an IBS system.
a. Trikha (1999) suggested that an IBS system can only be acceptable to
practitioners if its major advantageous can supersede the conventional
system. However, up to date, there is inadequate corroborative scientific
research undertaken to substantiate the benefits if IBS system. It is therefore,
arguable that the implementation of IBS is particularly hindered by lack of
scientific information.
b. A research by Kampempool and Suntornpong (1986) shows that
standardisation 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 standardised floor slab has to be used
although a 260mm thick floor slab can achieve the similar structural
performance. This would results wastage of material.
c. The selection of a new IBS has been hindered by lack of assessment criteria
set by the approving authorities. According to Trikha (1999), this
phenomenon has been even more detrimental to the development of an
indigenous IBS. With such reason, absence of assessment criteria has been
26
identified as the most important inhibitor to the introduction of IBS system in
the country.
d. Despite an intensive marketing strategy since 1980‟s in Malaysia to introduce
modular co-ordination, Trikha (1999) said its acceptance has received poor
responses for the building industry. As a result, even partial introduction of
IBS such as lintels, staircase, etc has not been possible.
e. Warszawski further added that there is a general decline in demand and
volatility of the building market for large public housing projects in most
developed countries makes an investment in IBS more risky when compared
with the conventional labour intensive methods. This reason is substantiated
by a cheap imported labour in several European countries.
f. The industrialisation of building process which emphasis is on the
repetitiveness and standardisation cause monotonous “barracklike”
complexes that very often turned into dilapidated slums within several years.
Warswaski (1999) pointed out that the 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 buildings.
g. Warszawski (1999) also mentioned that 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.
h. At university level, students are less exposed to technology, organisation and
design of IBS. The academic curriculum seldom includes courses that
incorporate a thorough and methodological manner, the potential and the
limitations associated with industrialisation in building. As consequences,
Warszawski (1999) proposed that there is a natural tendency among
practioners to choose conventional methods perhaps with occasional
utilisation of single prefabricated elements.
i. The weakness of existing industrialised building system is still in its
cumbersome connections and jointing methods which are very sensitive to
errors and sloppy work. Also, Din (1984) that commented standardisation of
joint and connection detail may impede the evolution of new technology.
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j. An adaptation of standardisation requires a tremendous education and
training effort. Hence, requires an initial immense investment cost.
Warsawski commented that this is one of the greater hindrances to the use of
modular coordination.
2.7 IBS in another point of view
The usage of IBS would reduce substantial amount of unskilled and skilled
labourers that are involved directly on site. This has been proven according to
Warszawski (1999) whereby a study was carried out in Israel to compare between
IBS and conventional construction method in 1984. The results shows that the use of
IBS has brought much saving in site labour up to 70 percent and saving on total
construction cost if compared to the conventional methods. Correspondently in
Singapore, the research conducted by Cheong (1997) shows that the use of fully
prefabricated system provides labour saving up to 46.5 percent as compared to the
conventional method. This would decrease on the dependency of foreign labour
workers. However this does not affect the country workforce. The usage of IBS will
open up many opportunities to the younger generations that seem to be reluctant to
be involved in the construction industry.
The usage of IBS can increase the professional workforce in Malaysia. One
of the areas that can be enhanced is the knowledge of the IBS components. The
research and development can focus on area to improve the local industry and the
dependence on the foreign technology can be reduced. The design should suits the
local social conditions, climate, materials and building tradition, which should be
given top priority. Lim (2006) mentions Architects, design engineers and contractor
strive to find optimum economic solutions for speed of erection and highest
specifications of the project.
Harwant et al (2003) proposed that the development of alternatives for IBS
can be started natural building materials and geological building materials. The use
of rock and concrete need not the only material used in manufacturing industrialised
28
building system. The natural building material may be considered are light clay,
natural plaster and monolithic adobe. The light clay can be used to make non bearing
wall while natural plaster such as lime, gypsum, earth plaster and casein paint are
appropriate options for finishing interior and exterior wall surfaces. The monolithic
adobe consists of unburned clay with straw as a binder used to build walls. Usage of
this material will ease the dependence on rocks and concrete which will assist the
environmental conservation efforts. This is especially true when the construction is at
remote area when material is a problem for construction.
The manufacturing of industrialised process of IBS need to be studied very
thoroughly so that it can meet the current local needs in terms of speed, quality and
cost saving. The standardisation of the manufacturing process through the
modularization of components can increase product variety without seriously
affecting the production cost. The standardization of manufacturing process enables
it to be accepted for the implementation of IBS.
2.8 Experiences and Implementation of IBS in Other Countries
IBS is gaining wide popularity among construction practitioners worldwide.
The implementation of IBS in other countries is using the local legislative context in
the building regulations. According to the findings by Thanoon et al (2003), it can be
seen that the international acceptance of IBS method into the construction industries
of respective countries clearly shows that such method is beneficial to the
construction sectors. Below are some reviews on the IBS acceptance in several
countries around the world.
2.8.1 Germany
A detailed investigation by Glass (1999), the German regulations are not too
specific of secondary requirements which encourage the use of IBS to be more
advantageous or economically viable than in United Kingdom. The IBS in Germany
29
is well established and the market is very competitive due to technological
advancement. The development of precast is well recognised especially the precast
internal and external wall as well as roof panel. Therefore Thanoon (2003) suggested
that it is economically viable to set up factories solely dedicated to the production of
precast concrete industry.
The German Building Regulations are based on model regulations that are
written mainly in functional terms and issued by the Federal Government. The
Federal Building Code includes both building regulations and planning law so the
building regulations include requirements which are mainly to ensure public health
and safety and matters concerning the design and layout of buildings and sites. The
building regulations are supplemented by technical regulations for building products
that differentiate between regulated and non-regulated products. Regulated products
generally comply with the technical regulations and suitability for purpose is checked
either by the manufacturer‟s certificate of conformity or a certificate of conformity
issued by an approved certification agency. Suitability of non-regulated products is
confirmed by compliance with general technical approvals, a certificate of inspection
and approval or a special agreement for individual cases.
In Germany, the building control system operates through a plan submission,
approval and inspection by local authority. Structural stability relies primarily on the
appropriate DIN Standards for construction methods and the materials used in
construction. Meanwhile the fire protection standards are set out in DIN 4102 and the
sound insulation technical requirements are contained in DIN 4019 that requires the
sound reduction of 53 dB in the wall.
2.8.2 Netherlands
The use of IBS in the Netherland consists about 10 percent of the total
housing market, although the conventional brick wall and masonry construction still
prevail in the country. Nevertheless, according to the research by Glass (1999), the
industrialised housing is steadily increasing due to cost saving up to 30 percent. This
30
is substantiated by standardised components, flexible manufacturing process and
improved industrialised building technique.
The basis of Dutch law on building work is the Housing Act. The Building
Decree which came into effect contains nationally uniform technical legislation. The
main points are of the Building Decree includes safety, health and energy economy,
the performance of the building by reference to standard and relevant certificates to
conformity and Technical Approval by manufacturers as a proof of meeting the
requirements. However, the municipal cannot impose separate technical requirement
on all the IBS elements.
Open building concept was introduced in Netherlands to meet the high
demand of mass housing production for its civilians. This concept has emphasized on
the application and usage of IBS components. According to Cuperus (1998), Open
Building is a multi facetted concept, with technical, organizational and financial
solutions for a built environment that can adapt to changing needs. It supports user
participation, industrialization and restructuring of the building process.
The Building Decree is published as fourteen independent chapters covering
the technical regulations for construction work and the state of existing construction
works. It contains a collection of performance requirements, by which building plans
can be tested using measurements or calculations and indicates, through a test value,
whether the requirements have been complied with. The builder can decide how to
construct and which materials to use providing the performance requirements are
met. The Decree refers to Dutch Standards concerning buildings and civil
engineering works (Category „A‟ Standards). Provision has been made in the
Building Decree for Dutch Standards to be replaced by harmonised European
Standards as these become available.
More codes were introduced thereafter, and this marks a milestone change in
the building industry in Netherlands. The building industry is changing from building
on site using basic building materials to an assembly process: complete and complex
building parts are made in the factory and assembled on the site into a building.
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Today, Netherlands is among one of the country that leads in the application
of IBS components in the construction industry. Its strong concept on the benefits of
Open Building which aims to optimize the quality of the built environment, by
improving the relationship between the customer and the building industry has
attracted many countries worldwide to seek the expertise advice from the
Netherlands. The OBS has indeed help to optimize building and construction.
2.8.3 United Kingdom
The use of IBS in Britain became more evident in the mid 1900s after the
widespread destruction of housing units during the Second World War. According to
Glass (1999), over 165,000 precast concrete dwellings had been built ranging from
small single bungalow to large high rise buildings by 1960.
In 1999, the precast concrete represents about 25 percent of the market for
cementations products. This includes a wide range of products used in the
construction industry such as suspended floors, structural blocks, paving, cast stone
and architectural cladding. Of these products, the suspended floors represent the
higher use with output in term of tonnes of product sold per annum.
Regulation 9 stipulates that the requirements of the regulations can be
satisfied only by compliance with the relevant standards. The relevant standards are
set out in this document, the Technical Standards for compliance with the Building
Standards Regulations 1990, as amended. To satisfy the regulations therefore the
design, materials and methods of construction must be at least to the standards set in
the technical standard. The provisions deemed to satisfy the standards are provided
for the convenience of designers only if they choose to adopt them. There is no
obligation to do so but if used properly deemed to satisfy solutions must be accepted
by the local authority.
In the technical standard in the Building Standard 1990, in the Chapter 9 Part
G2.6 sub C mentioned that the suspended floor using IBS elements need to provide
insulation above the panels. The non bearing prefabricated walls are required to
32
follow the BS 8297: 1995. The BS 476 specified the fire test and requirements for
structures and BS 8297: 1995 is the code of practice for design and installation of
non load bearing precast concrete wall cladding.
In BS 6750: 1986 specifies requirement for modular reference system,
positions of key references planes and the sizing of the building and their
components and material designed in compliance of principles of modular
coordination. It also specified the modular grids, positions of modular floor plane,
modular height and the modular space. The design specifications, joints and fits and
the dimensioning are standardized. On the other hand, BS EN ISO: 1999 are the
standardization of the construction drawings which guide in the representation of
modular sizes, lines and grids. With all this standards available, it is easier for the
designer and fabricator to standardize in terms of sizes, drawings and the concept.
IBS has played a huge role in the construction industry in Britain. In the
future, it is expected that IBS components will take over the conventional masonry
construction that has monopolise the market for a very long time already.
2.8.4 United States of America
IBS has begun as early as the 1930s as seen by the construction of
prefabricated steel houses by General Homes back then. However, due to price in
competitiveness, high capital investment and inconsistent local codes, the early
dream to popularise IBS as an innovative construction method began to fade off.
However, after the Second World War, the trend was brought up again due to the
rising need to resolve the critical shortage of houses.
According to Glass (1999), a study was carried out by Portland Cement
Association (PCA) indicated that 70 percent of buyers in the US market select their
dream house on the basis of cost/value alone. In other words, the advantages in terms
of architectural finishes, flexibility and good thermal insulation were perceived as a
secondary concern only. However, the mindset of buyers have eventually changed
and buyers to take into consideration of speed and ease of construction, and most
33
importantly, the quality of end product when purchasing a house, thus making IBS as
a popular choice of method of construction.
In the state of Georgia, there are several codes that are observed to ensure the
uniformity in the construction of industrialized building. The different sections of the
Codes specify different materials, method of construction or other requirements and
therefore the most restrictive standard will govern. If there are argument between
general requirement and specific requirement and the latter shall be applicable.
Alternate materials and construction method can be used but it needs the approval
from the Commissioner provided the purpose intended meet the specifications in the
technical codes.
In the Georgia Standard Building Code, the regulations includes the
specifications weight of building material for transportation and the minimum ceiling
height shall be 7 feet (2181mm). The local authority of the state has the power to
govern over the designer, manufacturer and the constructor. The designer is governed
through the submission of plan where as the manufacturer need to submit the quality
control manual for approval before the construction can be commenced. The quality
of the constructor installation of prefabricated is supervised by the representative
from the local authority.
In the United States of America, timber framed is mostly used for low rise
housing, whereas concrete precast system is being used intensively particularly in
area that are vulnerable to environmental hazards as such hurricanes and tornadoes.
Concrete precast system is also applied in the construction of high rise building in
the USA due to its speed and ease in construction.
With the setting up of The Building America Industrialized Housing
Partnership (BAIHP), more researches and findings are carried out intensively to
formulate the best technology and construction methods to further promote IBS in
USA. Through such organization, IBS is gaining fast popularity in the USA market
in terms of high rise and low rise structures.
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2.8.5 Japan
According to Nagahama (2000), the industrialisation of housing industry in
Japan started in 1960s and since then, the market share has changed dramatically
with the usage and application of IBS.
As reported, from April 1999 to March 2000, construction of prefabricated
houses in Japan represented 20 percent of all houses built in Japan during that period.
Out of that, the steel framing system dominated the prefabricated market with a 73
percent share, followed next by the application of wood framing which stands at 18
percent, while the reinforced concrete framing only accounted 9 percent of the
prefabricated market.
With reference to this, the wood-framed housing grew 2 percent and steel
housing grew 3 percent, while concrete framed housing experienced a major setback
of 12 percent. In spite of that, the Japan construction industry is still regarded as highly
integrated and automated production equipment and facilities to manufacture house
building components and offers home buyers both quality and aesthetic dream house.
2.8.6 Singapore
The need to accomplish large quantities of apartments in the early 60s for
urgent housing needs as quickly as possible has prompted The Housing and
Development Board (HDB) of Singapore to adopt the IBS method. The emphasis
then was less on aesthetics. By the mid 70s, the housing situation had improved and
more attention needed to be given to provide a total living environment for residents.
At this stage, the requirement for aesthetics and finishing quality began to emerge.
This trend carried on to the 80s and in the 90s, seeing new concepts like mass
customization emerging.
Based on the report by Tat and Hao (1999), during the period from 1973-
1979, HDB of Singapore has again took a brave initiative to attempt IBS in view of
the need for accomplishing 100,000 dwelling units of housing units. As a result of
35
continuous effort, the HDB has made a remarkable achievement in the adoption of
IBS for the construction of the public housing program. These initiatives are the
incorporation of modular co-ordination of its public housing designs, design
standardization and customization, prefabrication, and the mechanization of site
operations.
The setting up of HDB Prefabrication Technology Centre (PTC) in 1994
marks another milestone achievement in the application of IBS in Singapore. PTC‟s
main activities are to design, develop and produce prefabricated building products;
conduct research and development of advanced and innovative construction materials
and systems; manage and supply prefabricated building products; conduct training
and license its intellectual property rights.
The application of IBS in the construction industry in Singapore is gaining
high popularity due to its many benefits. Through its own research centre, HDB has
introduced major innovation in the area of IBS components, as such precast refuse
chute, precast ferrocement secondary roof panels, precast volumetric household
shelter, precast column, precast façade, and precast parapet and so on. Figure 2.9
show examples of innovative IBS components produced in Singapore.
2.8.7 Thailand
The application of IBS as an innovative construction method in Thailand is
gaining higher popularity as compared to the scenario of the construction industry in
Thailand way back in the 1970s. According to Buddhi (2004), in 2004, the
government of Thailand planned to build about 600,000 units within three years for
the low to medium income level citizens. Most of these family units are detached
houses.
Commissioned developers and designers have proposed different housing
systems. However, it is important to note that in terms of material, production and
construction, the design must be suitable for large scale construction within a limited
time and cost. In July 2004, the National Housing Authority (NHA) of Thailand has
36
Precast refuse chute Precast ferrocement secondary roof panels
Precast volumetric household shelter Precast column
Precast façade Precast parapet
Figure 2.9: Examples of innovative IBS components produced in Singapore
37
approved the usage of the Precast Large Panel Construction (PLPC). This marks
another milestone for the construction industry in Thailand, where several thousand
PLPC houses will be built within a period of several years.
PLPC is another example of IBS components widely used in Thailand. PLPC
structural system consists of normally reinforced precast concrete panels, precast
slabs and foundations. No beam and columns are used except at few locations. In
terms of the speed of construction, the total time required is significantly less than
the conventional system. According to Buddhi (2004), for a typical 2-3 bedroom two
storey house, the time required for casting, lifting, erection and completion of
structural system is about 2-4 days once the system is setup. This shows how fast a
typical house built based on IBS concept can reach, as compared to conventional
construction method. Figure 2.10 show the application of PLPC in the construction
industry in Thailand.
Other advantages of using PLPC, which includes mass production, no
removal of formwork, less or comparable structural cost, quality control, usage of
skilled labour, low initial investment, modularization and automation and durability
and long term performance. Thailand is one of the countries actively introducing IBS
construction method into its construction industry. It is predicted that the
Government of Thailand will be able to achieve its target in providing 600,000 units
of housing units to its low and medium income group, thus providing the basic
necessities to its civilians, thanks to the application of IBS in its construction
industry.
38
Casting of PLPC components PLPC Component Layout on Bed
Stacking of PLPC components PLPC components are lifted into position
An almost done PLPC house The magnificent product of PLPC
Figure 2.10: The application of PLPC in construction industry of Thailand
39
2.8.8 Denmark
According to Gibbons (1986), in Denmark, about 80 percent of the detached
houses produced since the mid-1960 was using IBS, most of it panelised system. The
IBS application in Denmark is aimed for domestic and export markets. For instance,
its international contractors such as Jespersen & Son and Larsen & Nielsen have
constructed many large-scale projects throughout the world, using prefabricated
concrete system produced from the local factories in their country.
In short, Denmark is not very lagging behind in terms of advancement in the
application of IBS in its construction industry. The construction companies from the
country are actively promoting IBS components from their country to the outside
world.
2.8.9 History of IBS in Malaysia
The initiative to use and introduce IBS in Malaysia started off back in the
early sixties, when the Minister of Housing and Local Government visited some
European countries and evaluated their building systems performance. Din (1984)
reported that, it was then that the two pilot projects using IBS concept was carried
out in 1964 where the first pilot project was 7 blocks of 17 storey flats and 4 blocks
of 4 storey flats which comprise of 3000 units of low cost flats and 40 units of shop
lots in Kuala Lumpur. The project implemented large panel system using the Danish
System with IBS concept of construction.
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, using French Estiot System. With reference to the two pilot projects, it
is found out that in terms of comparison of performance between IBS system and
conventional system based on cost, productivity and quality factor, the overall
performance of IBS is more competitive than the conventional method.
40
Since 1980‟s there are intensive marketing strategy launched by the
Malaysian government to introduce modular coordination, Trikha (1999) reported
that its acceptance has received poor responses for the building industry. As a result
even partial introduction of IBS such as lintels and staircase has not been possible.
Previously in the 7th Malaysian Plan, the country intended to construct about
800,000 units of houses for its population using the IBS construction. Indeed,
585,000 units were planned for the low and low medium cost houses. However the
achievements are disappointing with only 20 percent completed houses reported due
to use of conventional construction method. According to Ismail (2001), although the
government introduced numerous incentives and promotions to encourage housing
developers to invest in such housing category, the response is not so positive. Under
the 7th Malaysian Plan, the enforcement of Modular Coordination through the
Construction Industry Standard 1 and 2 only applies to the low cost housing projects
initiated by the Ministry of Housing and Local Government Malaysia (CIDB 2003a).
The enforcement by the local authorities did not apply to all the parties involved in
the construction contribute to the failure of 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 non conformance
leads to the use conventional method which is less risky to the developers.
In 1998, the Ministry of Housing and Local Government and CIDB has come
up with the Modular Design Guide which contain the modular coordination concepts,
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 of the clause mentioned that „11 meter square gross area‟ is
replacing the „10.8 meter square net area‟. This is suitable for the area of
room that has the dimension of 3000mm x 3600mm and using the modular
dimension.
41
b. The fourth line of the clause stated that „9.3 meter square gross area‟ is
replacing the „9.0 meter square net area‟.
c. The fifth line of the clause mentioned that „6.5 meter square gross area‟ is
replacing by „6.3 meter square net area‟.
In the conventional construction project the local authority only given to
inspect the work after the completion of the project. The government should look
into allowing the local authority to inspect the work in the manufacturing process up
to the construction stage and lastly to the project completion to ensure that quality is
not compromised.
In year 2001, the Government set the Malaysia Standard 1064 in order to
standardise the IBS components in terms of dimensions. However the MS 1064 still
have a lot of loop holes that still can be improved. The important specifications such
as types of material, design standard, connection types, construction method and the
system implementation are not included. These items will ensure the quality of IBS
components can be improved and the contractor can implement a standardised
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 as to allow for
technological improvements in construction method, system and etc.
According to findings of Lim (2006), many innovations 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 adaptation are 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.
42
2.9 Impediments to Progress of IBS in Malaysia
The government as the major key player in the construction industry has
spent billions of Ringgit over the past several Malaysia Plans to develop the country.
However the plans are characterised 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 construction industry. Salihuddin (2003) commented that the
government has not taken necessary actions for the globalisation and the
industrialisation of the construction industry. Meanwhile, Trikha (1999) added that
the selection of IBS has been hindered by the lack of assessment criteria set by the
approving authorities.
An IBS system can only be practised by the practitioner if its major
advantages are valuable compared to the conventional system. However up to date,
there is inadequate collaborative scientific research undertaken to substantiate the
benefits of IBS system. Therefore it can be clearly seen that the implementation of
IBS is hindered by lack of scientific information as commented by Razali et al
(2002). Warszawski (1999) emphasised that the academic curriculum in the
university seldom incorporate courses that technology, organisation, construction and
the design of IBS. Nonetheless Thanoon (2003) mentioned that lack of research and
development to use the local materials causes the dependence of foreign technology
can be expensive and the quality of products may be compromised.
The fragmented construction industry straddles over several professions and
business. Salihuddin (2003) pointed out that the professionals, builders and the
supplier do not communicate 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
43
venture capitalism in a proactive meaningful manner and as such effort in
universities and research institutions remain largely unexploited and unused.
All parties involved in the construction industry should collaborate and to
work together in order to achieve the full utilization of IBS in Malaysia. The
government plays a very important role in imposing new regulations, standards and
training in terms of knowledge, experience and construction method. Moreover the
standardisation of dimensions of material needs to provide a feedback loop from the
constructor to enable the implementation to be improved 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
their respective roles in the successful implementation of IBS.
2.9.1 Development of IBS in Malaysia
According to Badir et al. (2002), there are at least 21 suppliers and
manufacturers actively involved in promoting IBS in Malaysia. However, majority of
the IBS components are originated from the United States, Germany and Australia,
whereas Malaysia only contributed to a smaller portion of produced IBS
components.
This shows that there are still ample of rooms for improvement and thus
promoting the application of IBS as an innovative construction method in our
country is still widely open. Figure 2.11 shows the sources of IBS in Malaysia
according to the origin of countries.
According to Budget (2004), Former Finance Minister, YAB Dato‟ Seri
Abdullah Ahmad Badawi on 10 September 2004 during the Budget 2005
announcement, has encouraged the usage of IBS components in Government
building projects and would be increased from 30 percent to 50 percent commencing
2005. Housing developers, who utilize IBS components exceeding 50 percent, will
44
be given full exemption on levy imposed by CIDB. This shows that the Government
is trying to encourage the usage of IBS components in the construction projects in
our country.
Figure 2.11: The sources of IBS in Malaysia according to the origin of countries
(Badir et al, 2002)
According to CIDB (2003), only 15 percent of the local construction industry
has used IBS in Malaysia. Nevertheless, despite the high initial investment outlay,
some developers in Malaysia with sufficient economies of scale have taken proactive
steps and invested in IBS, mainly in formwork and structure. According to these
developers, IBS provided better and more consistent quality to their buildings, better
site management with less dependence on foreign workers.
According to Malaysian Industry-Government Group for High Technology
MIGHT (2003) during a meeting on 24 January 2003 chaired by Datuk Eddy Chen,
REHDA Immediate Past Present, it is acknowledged that:
IBS has been practised to a certain extent in Malaysia. PKNS, for instance,
have built over 25,000 housing units using industrialized systems. JKR also
Malaysia, 12%
UK, 4%
Austria, 8%
Australia, 17%
Germany, 17%
US, 25%
Other
Countries,
17%
45
reported that they are using IBS for government quarters being constructed all
over Malaysia
In JKR‟s case, they design the components (prefab slabs, beams, columns,
infill panels) and based on the specifications, the market comes up with
manufactured products. Their designs are such that they can either do
modular and IBS, or conventional
There are no less than 70 systems available in the market. As such, there is a
need to actually agree on a definition on IBS. With a proper definition, the
next course of action is to get acknowledgement from authorities, financial
institutions, etc.
That IBS should not only be related to high rise, but also low rise
developments and also commercial buildings
Modular coordination (MC) must be emphasized. Knowledge of MC at all
levels (including local authorities‟ personnel) must be enhanced. Everybody,
from owner to designer to authorities and contractors must familiarize
themselves with MC to prevent occurrence of huge mould modifications for
every new projects – which is cost ineffective
From consultants‟ point of view – currently they have to do 2 designs
(conventional and industrialised) because specifying the designs as
industrialised will result in the client getting very small number of tenderers
during tendering process
Agreed that there should be elements of incentivisation to IBS users –
developers, consultants etc. Incentives should also be given for partial IBS
usage.
Whether our human resource is ready to adopt IBS
Although the CIDB has drawn up the IBS Roadmap, Modular Design Guide,
catalogues of prefabricated components and many other guides with some reference
to implementation goals and timelines, achievements to date are unclear and of little
impact. Towards this end, it is necessary for CIDB to engage experts with
appropriate technical skills to undertake an in-depth study on what is required to
establish and promote IBS, including an industry-wide cost-benefit analysis, details
on the implementation plan with clear milestones and deliverables.
46
The Government should set time-frame to gradually reduce intake of foreign
labour into the construction industry. A monitoring mechanism will also need to be
set up to track progress of IBS industry development with objective key performance
indicators (KPIs). Vellu (2004) was quoted as saying; “successful implementation of
the shift to IBS is expected to help the government in meeting its target of decreasing
foreign labour dependence by 85 percent”.
For this system to be successfully utilized, both public and private sectors
would need to play their roles in educating the local construction industry. But aside
from voluntarily changing mindset, there must be some push factor to catalyze the
shift in mindset. Perhaps a good combination of carrot and stick, i.e. incentives and
regulatory requirements for the introduction and adoption of IBS should be the next
concrete plan of action to be spearheaded by CIDB to further promote IBS in the
construction industry in our country.
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. Precast, 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 in the
research of Thanoon (2003) that at least 21 of various manufacturers and suppliers of
IBS are actively promoting their system in Malaysia. 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 percent (CIDB, 2003b). The total registered
IBS contractors in Malaysia stand for 1,993 in year 2007 as shown in Table 2.2 and
Table 2.3 and registered IBS manufacturer in Malaysia until 2007 is 138, which
producing 347 IBS products available in the market as shown in Table 2.4.
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
47
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 would limit only safe and acceptable IBS panels are erected and thus CIDB will
lead this roles.
Table 2.2: Registered IBS Contractor (Active) in Malaysia by IBS Grade (B01, B02,
B12, B15 and B19 (2007)
GRADE SPECIALTIES TOTAL
B 01 Buildings and Industrial Pre-casting Work 28
B 02 Buildings and Industrial Steel Structure Work 516
B 12 Aluminum, Glass and Steel Work 232
B 15 Roofing and Steel Cladding Works 108
B 19 Special Framework 11
GRAND TOTAL 895
Source: CIDB Malaysia (Zuhairi, 2008)
Table 2.3: Registered IBS Contractor (Active) in Malaysia by CIDB Grade (2007)
GRADE NUMBER
G7 334
G6 52
G5 83
G4 42
G3 191
G2 76
G1 71
TOTAL 849
Source: CIDB Malaysia (Zuhairi, 2008)
48
Table 2.4: Registered IBS Manufacturer and IBS Products available in Malaysia
MATERIAL MANUFACTURER PRODUCT LOCAL FOREIGN
PC Panel, Frame,
Box 51 245 27 3
Steel
Frames/Panel
Components
30 45 16 1
Systems
Formwork 29 29 14 3
Timber Frames 28 28 13 2
TOTAL 138 347 70 9
Source: Suruhanjaya Syarikat Malaysia (SSM) (Zuhairi, 2008)
2.10 IBS Roadmap 2003 -2010
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
divided the IBS programme into the five main focus areas as shown in Figure 2.12
that reflect the inputs needed to drive the programme, each beginning with M. They
are Manpower, Materials, Management, Monetary, and Marketing (CIDB, 2003).
The inputs are then divided into its 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 time-frame. About 109 milestones
are set to be achieved in year 2010. The content of this Roadmap is focused towards
achieving the industrialisation of the construction sector and the longer term
objective leading towards Open Building Systems concept.
According to IBS Roadmap 2003-2010, the key elements of the roadmap are
as follows:
1. To have a labour policy that gradually reduces percentage of foreign workers
from the current 75 percent to 55 percent in 2005, 25 percent in 2007 and 15
percent in 2009,
49
Figure 2.12: IBS 5M Component Elements (IBS Roadmap 2003)
2. To incorporate IBS/MC in professional courses for architects, engineers and
others,
3. To incorporate syllabus on IBS/MC in architecture, engineering, building
courses in local universities,
4. To enforce Modular Coordination (MC) by local authorities through Uniform
Building by Law (UBBL),
5. To develop catalogue of building components and standard plans for housing
6. To develop IBS Verification scheme,
50
7. To enforce utilisation of IBS for 30 percent of total government project
(building) in 2004 and gradually increasing to 50 percent in 2006 and 70
percent in 2008,
8. To introduce constructability programme for all private building and
enforcement from 2008, and
9. To provide tax incentives for manufacturer of IBS components
10. To offer green lane programme for users of standard plans (designed using
standard IBS Components and MC), and
11. To start vendor developing programme, training and financial aid.
As such, it is imperative to research fraternity and construction industry
stakeholders to collaborate and ensure that any research project is not only able to
create new knowledge but must also be aware of the requirements needed to bring
the idea to the market and apply. In order to formulate the R&D for IBS strategy,
CREAM has organised workshops, seminars and dialogue with the industry players
from 2006 and 2007. This document is based from the outcome of the workshops and
discusses CREAM‟s strategic direction that address long term requirement for R&D
on IBS for the Malaysian construction industry.
One of the important milestones in the roadmap is the introduction of
Modular Coordination (MC) concept. The system allows standardisation in design
and building components (CIMP, 2006-2015). It will encourage participation from
manufactures and assemblers to enter the market, thus reducing the price of IBS
components. In essence, MC will facilitate open industrialisation which is the prime
target of the roadmaps. The proposed enforcement of using MC through Uniform
Building By-Law (UBBL) would encourage the adoption through standardisation
and the use of IBS components. However, until the end of 2007, the UBBL have yet
to be amended to include MC regulations (Zuhairi et al, 2008).
Another important step taken by the government of Malaysia is to introduce
incentives for IBS adopter. The exemption of the CIDB levy in 0.125 percent of total
cost of the project according to Article 520 on contractors that implanted some kind
of IBS in at least 50 percent of the building components was introduced effectively
from 1st January 2007. In the first half of 2007, there were only 24 residential
51
projects qualified for the levy exemption. It is a very small percentage of total 417
residential projects during that period (Zuhairi et al, 2008). It shows that awareness
among developers and contractors on the levy exemption is still very low.
IBS Centre established in 2006 at Jalan Chan Sow Lin, Cheras, Kuala
Lumpur will be one-stop centre of IBS related programmes initiated by CIDB,
provide the training and consultancy on IBS and showcase IBS technology through
the demonstration project. The obligation to implement IBS strategies and activities
from this centre serves concurrent both to improve performance and quality in
construction, also to minimise the dependency of unskilled foreign labours flooding
the construction market.
2.10.1 IBS Roadmap Mid-Term Report
The IBS Centre has prepared but not yet published IBS Roadmap Mid-term
report to study the current status of IBS adoption in Malaysia on October 2007. The
report has highlighted the concerns that were adapted from paper published by
Construction Research Institute of Malaysia (CREAM) by Zuhairi et al (2008).
The report highlighted that high rise development and „factory-like‟ building
tend to have higher adoption of IBS than landed properties and small commercial
units. At presents, common practice shows manufacture of IBS components are
involved only after tender stage of the value chain. IBS need to be addressed in the
design stage to be successful adopted.
According to Zuhairi (2008), whilst there is no empirical data, there is some
anecdotal evidence, suggest that there has been sporadic dumping of sub-standard
foreign IBS product in IBS. A mechanism to ensure IBS products marked to an
acceptable standard must be introduced in the manufacturing process. There is yet
any certification or accreditation of components companies and installers in place.
Smaller contractors view IBS as threats and not as opportunities. There is lack of
integrated action plan to implement the IBS Roadmap 2003-2010.
52
It seems that most locally developed products based on traditional materials
such as reinforced concrete and that most using innovative materials are based on
imported technology. Until year 2007, vendor development programme have not yet
been performed. The certification of product and installers has yet to be implemented
until the year of 2007.
The adoption of IBS in Malaysia is just client driven. The contractor only use
IBS as alternative option, either explicitly or through challenging time and quality
requirements, demanded by clients. Out of 109 IBS Roadmap milestones, only 54
milestones have been achieved until year 2007.
2.11 Barriers to the Implementation of IBS
Clearly, the benefits offered by IBS are immense and plausible. It has been
six years since the launching of the IBS Roadmap 2003 and is about the end of the
mission of industrialising construction. The construction industry‟s stakeholders are
little bit sceptical on using IBS product. It is 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 programme so far. 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 datelines. Notwithstanding these achievements a number of implementation
snags were identified as being potential hurdles to the implementation of the
roadmap.
Warszawski (1999) pointed out some of the barriers in implementing
industrialisation in construction industry. There are decline in demand and volatile of
building market make an investment in IBS more risky compared to conventional
labour intensive method. Prefabrication elements are considered inflexible with
respect to changes with may required over its life span. At university level student
are less exposed to technology, organization and design of industrialised building
53
system. An adaptation of standardization requires a tremendous education and
training effort. Standardization of building elements face resistance from
construction industry due to aesthetics reservation and economic reasons
(Kampempool et al, 1986).
Trikha (1999) cited the hindrance to the use of IBS due to lack of assessment
criteria set by the approving authorities to urge the developers to use IBS. Poor
response from the construction players to modular coordination despite heavy
promotions and incentives from the government is also a hindrance to the successive
implementation of IBS in Malaysia. As a result, partial introduction of IBS such as
lintels and staircase has not been successful compare to the traditional cast in situ
design.
Meanwhile, Lim (2006) also highlighted ICT issues, which are concern with
the data and information available to the system, users, clients, establishment of
manufacturing layout and process, as well as allocation of resources and materials.
Transportation of panels and modules is much more difficult than transporting the
sum of their part. A 20 percent damage rate is not unusual during the first couple of
years in IBS project.
Thanoon et. al. (2003) also highlighted cheap labour cost is the main barriers
to the expedition of IBS. There are wide swing in house demands, whereas mainly
caused by the high interest rate and low performance in economical factor. He also
pointed out lack of skilled construction workforce which severe the situation. The
nature characteristics of construction project which are fragmented, diverse and
involve many parties. There lack of local R&D and novel building system that use
local material, which makes IBS often relies to imported technology from other
countries. There are also insufficient incentive and promotion from the government
to use IBS.
Rationality of IBS depend on many factors; design, standard, volume and
consistency (Payne, 1977). The government of Malaysia still feels that the usage of
IBS is still low despite the plausible potential. From the survey conducted by CIDB
Malaysia in 2003, the usage level of IBS in local construction industry stands at 15
54
percent (CIDB, 2003b). Zuihairi et al (2008) reported 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. There is no mandatory
requirement on any certification or accreditation of components, companies or
installers in place.
Rahman et al (2006) pointed out the hurdles in IBS implementation, which
reflected that the transport and joining skill cannot overcome inadequate in volume,
fixed cost of machinery and structure can push unit cost up if demand is insufficient,
which often is the case of absence of public sector support. If considered the
additional management and sales cost, the total amount of savings by adopting IBS
would be less than 10 percent. Installation of heavier and more complex components
would further raise the capital costs, volume requirements and uncertainty.
IBS cannot save the overall labour cost by spending more lighter-weight
component, which warrants more labour cost. Any reported larger saving was not
due to increase of efficiency of IBS, but mainly due to reduction of quality or to use
less land, where this is not the true intention of IBS. Low labour cost of the clay-
brick industry using rudimentary technique and unskilled labour has made labour
intensive methods able to compete successfully with a production process.
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. Performance of high quality components is often
offset by patchwork or poor fits and by early cracks. Moreover, the method itself
involving mechanized system and skilled worker introduces demand of precision not
needed in other method. A country cannot afford to build large volume of dwelling
or close the housing deficit fast regardless of time saving if these are to be built with
imported mould and cranes. Speed of construction converted to monetary saving is
very small.
Rahman et al (2006) further added to the list of challenges to adopt IBS in
Malaysian construction industry is that the term IBS is often misinterpreted with
negative meaning linked with 1960‟s industrial building. These building are normally
55
associated with low quality of building and unpleasant architecture appearance. The
industry is lack of knowledge and exposure to IBS technology and design. There is
lack of local design feasible of IBS system in the market to fulfil the requirements.
This has something to deal with the lack of general awareness among construction
players themselves.
Hussein (2007) also highlighted the barriers in implementation of IBS are
mainly the mindset problem towards achieving acceptance by the construction
community. The costs of using IBS exceed the conventional method of construction
given the ease of securing cheap immigrant labour. IBS design concept is not being
taken into consideration at the onset of the project Designers will not design using
components as they not find the components in the market, whilst producers will not
produce components as they do not see design using components .He also pointed
out that there are unenthusiastic acceptance of IBS among designers and developers
especially from private sectors.
Lim (2006) stated the following shortcoming in his research to IBS
implementation in Malaysia. He also pointed out the structure of construction
industry is considered fragmented where the whole supply chain get their own
strategy and agenda. The problems faced by the construction industry are also due to
inconsistency of policy guideline implementation and support from the government.
The industry is uncompetitive due to lack of open collaboration. Contractors
in Malaysia are obligate to close system and getting supply from the same
manufacture throughout the construction. IBS need mass production to achieve
economic viability. However, in Malaysia there is no assurance of continuity in the
production of components. Local authorities are unlikely to make change in local
building regulations that require a lot of time and cost to establish legislative
economic condition Contractors are keen on conventional method because they are
familiar with the method. Changing method or trade will need more investment to
train the workers, least or buy machinery. As a result small contractors are not
interested in IBS
Realising 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 continued to conduct three
56
series of IBS workshops session with the industry between 2006 and 2007. After a
lengthy deliberation with the stakeholders, it was concluded that the factors
contributing to the delays of IBS implementation and other issues related to IBS are
lack of push factor for authorities and responsible government bodies by laws and
regulations. The professionals in Malaysia are lack of technical knowledge about IBS
components.
IBS require onsite specialized skills for assembly and erection of
components, where there are lack of these supportive specialists. There is also lack of
special equipments and machinery which hampered work. The mismatch between
readiness of industries with IBS targets by the government prone to be crucial.
Participation from Bumiputera contractors as an erectors or manufactures was also
insufficient. There is lack of building projects for contractors to secure project in
construction.
The main reasons for the low adoption of IBS in Malaysia as stated in
Construction Industry Master Plan (CIMP 2006-2015) are lack of integration in
design stage and poor knowledge. IBS manufacturers are currently involved only
after design stage. This lack of integration among relevant players in design stage has
resultant in need for plan redesign and additional cost to be incurred if IBS is
adopted. Client and approving authorities have poor knowledge of IBS compared to
architects and engineers. Familiarity with IBS concept and its benefits is vital to its
success because IBS requires different approach in construction.
The barriers of IBS implementation in Malaysia can be summarised and
categorised in several themes, which are standardisation and quality issues, issues in
consumer perception, issues in professional perception, process and supply chain,
technology, training and education, finance and costing, incentive and
communication issues.
2.12 Construction Industry Master Plan (CIMP) 2006-2015
CIDB together with the captains of the construction industry have drafted
Construction Industry Master Plan (CIMP) 2006-2015. The importance of research
57
as stipulated in the CIMP‟s fifth Strategic Thrust is reflected in the fact that it is the
defining tool to generate innovativeness that improve the quality, performance and
standard of the construction industry through R&D. The importance of ICT for
construction is explained in Strategic Thrust 6. This thrust plays significant roles in
transforming design and building process in IBS from virtual to reality. The expected
target in year 2015 for Strategic Thrust 5 which gives emphasis on IBS and Strategic
Thrust 6 is highlighted in Table 2.5.
Table 2.5: Expected Target of CIMP Strategic Thrust 5 and Strategic Thrust 6 by
year 2015
2.13 Summary
So, if viewed positively, there is a great potential for IBS to grow in the
country. Nevertheless, the commitment and cooperation between the public and
private sectors is paramount in ensuring the successful implementation of building
industrialisation.
Also, the Malaysia‟s construction workforce is aging and shrinking as
progressively fewer young enter the industry. This phenomenon prompts the industry
to rely heavily on foreign workers. If, the demand for labour remains the same and
the supply decrease, construction cost will increase and eventually pass on this cost
to the home buyers. Hence, the industrialisation of building construction method and
the evolution of construction technology are inevitable and plausible.
58
This section has focused on some broader issue that could affect the take-up
of industrialised building system (IBS) in Malaysia. Despite various economic and
non-economic benefits of IBS, its utilisation is not well accepted by the construction
players. Therefore, various informative programs such as seminar, colloquiums, and,
conferences or perhaps the collaboration with the public universities should be
devised to enlighten the private sector as well as the public sector.
There are many types of IBS existing in Malaysia: formwork precast load-
bearing wall panel, precast frame, precast floor and hollow core slab, sandwich
panel, block panel, and steel frame. These IBS represent most of the IBS that exist
worldwide. Quality, speed of construction, and cost savings are the main advantages
of these systems. These factors are very important in implementing the Ninth
Malaysia Plan. The main disadvantages of the IBS in Malaysia are that they are
highly capital intensive and there is a need for experts at the construction site for
some of them. The main reason to recommend the use of IBS in Malaysia is that the
raw materials used in the IBS have to be produced locally in order to overcome the
shortages that are being faced by the IBS construction industry.
CHAPTER 3
RESEARCH METHODOLOGY
3.1 Introduction
Research methodology is the method that used to find, collect, analyse data
and therefore giving result based on observation. The proper planning and detail
study to the flow of the research methodology is crucial in order serves as a guide in
order to achieve the objectives and scopes of the study. This chapter shall further discuss
in detail the research procedures, from how the data is collected till how it is processed
and analysed to achieve the objectives and scopes of the study.
This chapter aims at elaborating the methodological process that used to carry
out the research based on the objectives of the study. This is including the literature
review and also the preparation of questionnaire in order to obtain the input that are
required.
3.2 Research Methodology
This section of study would focus on the method of study to be carried out to
achieve the objective of this report. Therefore, every measure taken must be appropriate
and relevant to the related topic of study. Three approaches have been throughout this
study to gather reliable and relevant data. The approaches are:
a. Literature review
b. Handing out of questionnaire
60
c. Reviewing the effective strategic formulation method
The research procedures are as shown in Figure 3.1.
Discussion with supervisor
Determine research topic
Identify research problem, issues and
objective of the studies
Objective 1:
To identify readiness of
contractors and
designers to adapt IBS in
their construction
projects
Objective 2:
To determine barriers
of the implementation
of IBS in Malaysian
construction industry
Objective 3:
To identify ways to
enhance the
implementation of IBS
in construction industry
Literature review on previous researches,
thesis, journals and other publication
Prepare proposal paper for pre-project
presentation
Data collection
Distribute Questionnaires
References, Technical papers, journals
Data processing
Analysis and discussion
Conclusion and Recommendation
Figure 3.1: Research flow chart
61
3.3 Literature Review
Literature review is an important part in the study in terms of gathering
secondary data. The previous researches that were done provide important
information and also served as a guideline in order to help better understanding of
the study. Literature review help scope down the researches by eliminating a lot of
work that were previous done by other researchers, it provide as a very good
guideline to pointed out what area needed to be focused in this research.
3.4 Questionnaire
Questionnaire is a set of pre-formulated and written questions that the
researchers would like to ask to respondents and record their answers. Questionnaire
can be an efficient data collection tool when the researcher knows exactly on the
information that is needed and how o measure the variables of interest. Thus, all
questions should be clear, understandable and obtain no ambiguity. Data validation
was conducted after the questionnaires had been collected. In the process of data
validation, the answers obtained from the questionnaires will be checked for
accuracy and suitability for this research purpose.
3.4.1 Sampling of Data
There were about 100 copies of questionnaires distributed to the targeted
respondents. Respondents for the questionnaire in this research are consisted of
contractors, consultants, developers, architects and quantity surveyors in Malaysia.
Handing out questionnaire is an approach to determine the current barriers of
the implementation of IBS that have been practiced among the construction players
in Malaysia. It was designed to gather and verify the information from literature
review. The method of distribution and collection of the questionnaire survey
encompass the following:
62
By mail and returned via mail through stamped self addressed envelope
By conforming through telephone calls and dispatching the questionnaire.
By hand distributions for selected respondents
By e-mail questionnaire method
3.4.2 The Design of Questionnaire
Questionnaire is an effective way designed to gather and verify the
information which from literature studies. However, the limitation of questionnaire is
that it is subjected to the willingness and cooperation of the respondent in completing
the questionnaire. Therefore, it is necessary to design the questionnaire as straight-
forward as possible to obtain information related to the objectives of the study.
Another important criterion when designing the questionnaire is the time to complete
it. It should be designed to be completed in the shortest time possible for the
convenience of the respondent as the workload of the respondents is usually heavy.
The questionnaire consisted of five parts – general information of respondent,
a survey on their experience and readiness adapting IBS in construction projects,
factor that affecting development of IBS, barriers of adapting IBS in construction
industry and lastly ways to enhance implementation of IBS. Respondents were
suggested to attach their business cards or company stamp to the questionnaire
forms. The information gathered was as follows:
Section A: General information of the respondent
Name of respondent
Profession
Position
Working Experience
63
Section B: Experience and readiness adapting IBS in construction projects
Experience with Industrialised Building System (IBS)
Experience with various types of IBS system
Readiness of using IBS System in building projects
Section C: Factor that affecting development of IBS
Policies and Incentive
Quality expectation
Productivity
Technical
Financial
Management
Section D: Barriers of adapting IBS in construction industry
Product support
Marketing
Funding
Certification
Sharing the Best Practices
Section E: Ways to enhance implementation of IBS
Education, training and awareness
Incentives from government
Standardisation
Promotion
Enforcement
More research and development
64
3.5 Methods of Analysis
The information and data gathered through questionnaire were compiled and
processed using average index method in relation to the objectives and scope of
study. Two statistical methods were applied, namely descriptive statistic and
inferential statistics. Result from the findings will be presented in the form of graphs,
histogram and pie chart for easier understanding.
3.5.1 Average Index
Average index is being calculated based on the formula of:
Average Index = aixi
xi
Where,
a = constant, weighing factor for i,
x = frequency of respondent
i = 1, 2, 3… n
A scale of 5 categories has been used for the average index method in order
to show priority. The scales of 5 categories are:
1 Least Agreed 1.00 to 1.50
2 … 1.50 to 2.50
3 Moderate 2.50 to 3.50
4 … 2.50 to 4.50
5 Mostly Agreed 4.50 to 5.00
65
3.5.2 Frequency Analysis
The collected raw data are required to be separated in a table of frequency to
show the distribution of each data collected.
3.5.3 Rank
Rank shows relative position or ordering when comparing the issues in the
same category. Rank is based on the average index. Higher rank with low rank
numbers unless mentioned otherwise are generally have more importance or
influences in terms when come to comparison and vice versa. It is very useful in
order to highlighted and list out of its importance.
3.5.4 Standard Deviation
In this research, standard deviation is used as a measure of the variability or
dispersion the data set from frequency analysis. A low standard deviation indicates
that the data points tend to be very close to the same value (the mean), while high
standard deviation indicates that the data are spread out over a large range of values.
It is used to verify the pattern and distribution of the collected data that assist in
when doing analyses in respected category.
3.5.5 Comments
Comments come in situational which are classification of the analysed data
that based on the average indexes, ranks, and standard deviations of the data. It turns
the numbers in the analyses to more meaningful phrases that could be interpreted
easier by others.
66
3.6 Summary of Chapter
This chapter describes in detail the flow of the study from the initial stage to
the end in achieving the objectives. The choices of the methods used is highly
depends on the study. For this study, questionnaire survey is used to gather the data
of the study and percentage analysis are used to analyze the data collected.
CHAPTER 4
ANALYSIS AND DISCUSSION
4.1 Introduction
This chapter focuses on analyzing the results gathered from the respondents
through interview and questionnaire. Since time allocated for the distribution and
collection of the questionnaire is very limited, the distribution of questionnaire is
limited to the respondents within the coverage of the researcher only.
The data collected were converted into more meaningful, useful and
informative formats that are in the form of tables and figures. The data also were
expressed according to the suitability of the analysis itself. The questionnaires were
distributed into different parts enables the analysis be done systematically and
reflects a logical result.
4.2 Distribution and Return of the Questionnaire
There were about 100 copies of questionnaires were distributed to the
targeted respondents consisted of architects, contractors, developers, consultants and
quantity surveyors. By the cut off date, the researcher managed to collect back 30
useable questionnaires from the respondents. This constitute of a sum of 30 percent
response rate. According to Fellows et al (1997), the normal expected useable
response rate is ranging from 25 percent to 35 percent. Therefore, the total response
received is considered sufficient for the purpose of this research.
68
The return percentage of the distributed questionnaire is as shown in Figure
4.1. From Figure 4.1, it is shown the return rates of the questionnaires were ranged
from 25 percent to 40 percent. In this research, the data collected by using email and
self collect method secure a higher return rate than other distribution method.
Questionnaires were sent by email to respondents who worked in the construction
industry. Besides that, the researcher also makes a few visits to construction firms
around the local area to distribute the questionnaire by hand. This method is slow as
the distribution is limited and the distance from one to another place is far. However,
distribution of questionnaire by postal have even lower response rate than the other
method.
Figure 4.1: Return Percentage of Questionnaire by the Respondents
4.3 Question Structure
The sample of the questionnaire can be referred in Appendix A. The
questionnaire is divided into five sections as described in Chapter 3. The analysis
mainly focused into three parts as discussed as follows:
0
5
10
15
20
25
30
35
40
Architect Contractor Developer Consultants
(C&S)
Quantity
Surveyor
Pee
cen
tag
e o
f R
etu
rn (
%)
Respondent
69
4.4 Respondent information
4.4.1 Respondent Distribution
Figure 4.2: Collected returns of usable questionnaires
Figure 4.2 shows the returned useable questionnaires of the different types of
respondents in the construction industry. 43 percent out of 30 useable questionnaires
were from contractors, which represent the largest groups of response in this
research. Contractors provide valuable information as they are those who deal with
the front line of the construction. They are those who face problems in this
competitive construction industry. Therefore, the result from these respondents
would give a clear overview of current level of implementation of IBS in the
Malaysian construction industry.
Architect
20%
Contractor
43%
Developer
7%
Consultants
(C&S)
17%
Quantity Surveyor
13%
70
4.4.2 Respondent Position
Referring to Figure 4.3 shows different level of position of the respondents in
the construction industry. Most of the respondent is from the technical level who
responsible for the overall technical work of the firm. The architect / engineer /
quantity surveyor / other technical staff consist of 34 percent of the total respondents.
This group of respondents is the frontline of the people who in contact with the
design stage of the construction projects. Their opinions are very useful and provide
true insights to this research. Besides that the other top related managerial personnel
and management level personnel also can provide valuable information to the
research.
Figure 4.3: Current Position of Respondents in Construction Industry
4.4.3 Respondent Experience in Construction Industry
Figure 4.4 and Figure 4.5 illustrates experience of the construction industry
and experience of the construction industry respectively. In Figure 4.4, the
respondents mainly have more than ten years of experience in construction industry
Director / CEO /
General Manager /
other top related
managerial
personnel
10% Project manager /
manager etc
23%
Architect /
Engineer /
Quantity Surveyor
/ other technical
staff
34%
Site supervisor /
Contractor
23%
Others
10%
71
(47 percent). Identically, Figure 4.5 shows most of their construction firms (60
percent) also have more than ten years of experience in construction industry.
Figure 4.4: Respondent Experience in Construction Industry
Figure 4.5: Construction Company Experience in Construction Industry
4.5 Readiness of adapting IBS in construction projects
4.5.1 Experience of IBS in Construction Industry
The first stage to identify the readiness of adapting IBS in construction
projects is to identify the respondent experience with IBS. There are four parameters
to be questioned in this section as presented in Table 4.1.
1-4 years
33%
5-9 years
20%
more than 10
years
47%
1-4 years
13%
5-9 years
27%more than 10
years
60%
72
4.5.1.1 Knowledge in IBS
The first question is to identify their knowledge with the terms IBS prior of
this research. Meanwhile the second question is to examine their actual knowledge
with IBS. From the questionnaires survey analysis, the result shows that only about
37 percent of the respondents know about IBS prior of the survey (by considering
respondents that choose answer 4 and 5). There are 27 percent of the respondents
having little or no idea what actually does IBS means (respondents that choose
answer 1 or 2). The analysis to this 27 percent of respondents that belong to this
category are further analysed to relate it with the general information of the
respondent. This analysis is further illustrated in Figure 4.6.
Table 4.1: Respondent Experience with IBS
Score Frequency Analysis Average
Index
Std
Dev Comment
1 2 3 4 5
Know about IBS before this? 2 6 11 9 2 3.10 1.03 Average
Possess knowledge about IBS? 3 7 15 3 2 2.83 1.02 Below
Average
Have experience using IBS
component in building
project?
8 9 10 2 1 2.30 1.06 Poor
The number of projects that
use IBS (1 = 0, 2 = < 5, 3 = 5
to 10, 4 = 10 to 20, 5 = more
than 20)
12 11 3 3 1 2.00 1.11 Low
Figure 4.6 show that all the C&S consultants have average or good
knowledge in IBS. Meanwhile 38 percent of the contractors have little or low
knowledge in IBS, which is considered the highest in this analysis. The “developer”
group is not considered in this analysis because the data obtained from the sample
size is not sufficient in order to generate appropriate analysis. From this figure shows
that the construction players that involved in the design process i.e. consultant and
architects have higher knowledge with IBS compared to those who does not involved
in design process, which are the contractors and developers.
73
Figure 4.6: Knowledge of IBS according to their profession
4.5.1.2 Experiences in IBS
The third part of Table 4.1 is to analyse the experience of the respondent in
using IBS in their building projects. Table 4.1 shows that majority of the respondents
for this research with average index 2.30 has low level of experience of using IBS in
construction industry. There are only 10 percent of the respondent have good or
excellent experience of using IBS in the construction industry. The last part for Table
4.1 shows that over 76 percent of the respondents have experiences in less than five
construction projects that use IBS.
4.6 Respondent experience with types of IBS
Table 4.2 shows the respondent experience with types of IBS. Generally, the
overall experience with each type of IBS is at low level with average index range
from 2.13 to 2.77. This can be classified as „poor‟ and „below average‟ as in Table
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Architect Contractor Developer Consultants
(C&S)
Quantity Surveyor
little or low knowledge in IBS average or good knowledge in IBS
74
4.2. Respondents have more experiences in block work system and steel frame
buildings and roof trusses.
The most popular types of IBS in the construction projects in this research is
the block work system which have average index of 2.77. Such system uses block
work to eliminate the uses of column and beam in simple single storey of building
for example of public toilets and utilities.
The second most common type is reinforced concrete buildings with precast
concrete slab which has average index 2.47. Such systems are also known as hybrid
system because it uses conventional method and precast slabs. In some situation this
method are prove to be more handy where the projects does not afford to involve in
the volume that enables customised type of precast columns and beams. The uses of
precast slabs which come in standard form factor and sizes greatly reduce the time
and work needed to be performed in site especially for those client driven fast track
project like Tesco and Jusco etc.
Table 4.2: Respondent experience with types of IBS
Score Frequency Analysis Average
Index
Std
Dev Comment
1 2 3 4 5
Precast concrete framed
buildings; precast concrete
wall buildings
5 13 5 7 0 2.47 1.04 Poor
Reinforced concrete
buildings with precast
concrete slab
8 6 7 7 2 2.63 1.30 Below
Average
Steel formwork system 10 12 3 4 1 2.13 1.14 Poor
Steel framed buildings and
roof trusses 5 8 9 6 2 2.73 1.24
Below
Average
Prefabricated timber framing
systems 9 13 4 3 1 2.13 1.07 Poor
Block work systems 6 7 8 6 3 2.77 1.28 Below
Average
Prefabricated timber framing system and steel formwork system have the
lowest score which average index of 2.13. The economic factor of timber system has
drawn back the usability of such system. Meanwhile the steel formwork system is yet
75
to gain popularity in Malaysia as the timber formwork is a cheaper option and
solution to most construction projects.
Figure 4.7 shows the percentage of respondents that have good experience in
at least one type of IBS (select at least one 4 or 5 in at least one type of IBS listed in
Table 4.2). According to Figure 4.7, it shows that the quantity surveyor do not feel
themselves have the appropriate level of experience in all types of IBS as described
at Table 4.2. The „does not have experience in at least one type of IBS‟ means the
respondents have ticked indexes 3 or below in the questionnaires. 68 percent of the
contractors have good or excellent experiences in at least one type of IBS.
Figure 4.7: Experience analysis in at least a type of IBS
On the whole, the implementation of IBS in the construction projects is at
poor level which being expressed in average index of less than 2.80. The confidence
level for the respondents answering these questionnaires is at poor level. IBS
involves high construction cost, high degree of repetition, lack of awareness and
involving skilled workers to install the system itself that may require much expertise
and might be expensive at the same time.
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
Architect Contractor Developer Consultants
(C&S)
Quantity
Surveyor
Have experience in at least a type of IBS
Does not have good experience in at least one type of IBS
76
4.7 Readiness of using IBS in building projects
Table 4.3 shows the readiness of adapting IBS in building projects. The
readiness of adapting IBS is considered as average as shown in Table 4.3. The
respondents feel that they were most prepared in term of labour if considering of
each sub section, which average index achieve 3.67. This is followed by material
which has the average index of 3.60. The respondents are most prepared in these two
categories.
Table 4.3: Readiness of using IBS in building projects
Score Frequency Analysis Average
Index
Std
Dev Rank Comment
1 2 3 4 5
Overall Readiness 1 10 12 5 2 2.90 0.96 - Average
Equipment
(Components &
machines)
0 4 14 6 6 3.47 1.04 4 Average
Technical Knowledge 2 6 8 12 4 3.31 1.17 5 Average
Labour 2 0 10 12 6 3.67 1.22 1 Above
Average
Material 0 4 10 10 6 3.60 1.17 2 Above
Average
Support (i.e. supplier,
manufacturers etc) 0 4 12 8 6 3.53 1.16 3
Above
Average
Design Standard 0 10 10 8 2 3.07 1.16 6 Average
Meanwhile the readiness of using IBS is in terms of technical knowledge
having the lowest rank in this survey. This shows that what highlighted in
Construction Industry Master Plan (CIMP 2006-2015) is true where poor technical
knowledge is one of the main reasons for the low adoption of IBS in Malaysia. This
lead to lack of integration caused IBS manufacturers involved only after the design
stage. This lack of integration among relevant players in design stage has resultant in
need for plan redesign and additional cost to be incurred if IBS is adopted. In this
research also pointed out where architects tend to have lower experiences with
various types of IBS than contractors and engineers.
77
4.8 Factors affecting the development of IBS
The factors affecting the development of IBS are as discussed in Table 4.4.
There are six categories of factors as pointed out by Iwani (2008) and each of the
categories has its own breakdown factors as shown in Table 4.4. The different
method of approaches is used in this research compared with what that has been
conducted in previous research. The most important factors affecting development of
IBS is the good quality control and the speed of construction that IBS provide.
Besides that, the respondent believe that certification of products, process and people
is the second most important factors in implementing IBS in the construction
industry. Meanwhile, attractiveness of potential margins and incentives in increase of
government project using IBS is also the other important factors in implementation
of IBS.
The heavily mechanised approach has displeased a substantial number of the
labour force from the building construction industry. IBS is a tremendous need for
expert labour at the construction site. Therefore extra costs are needed to train the
semiskilled labour force for highly skilled jobs. The main reasons for delay in early
completion of projects in IBS construction industry are supply delay, bad weather,
and shortage of raw material. In some cases, the main reason for the delay was the
lack of labour experience. This is because certain types of IBS construction are still
new in Malaysia and the labour force is still not familiar with the special erection
procedure required by those systems.
4.9 Barriers in the implementation of IBS in construction industry
For this research, the barriers of adapting IBS in construction industry were
divided into five categories as shown in Table 4.5. In these categories, the most
identifiable category is funding which have average index of 3.70. The least
influential barriers is the marketing category which of 3.35.
78
Table 4.4: Factors affecting the development of IBS
Score Frequency Analysis Average
index
Std
Dev Rank
1 2 3 4 5
Policies and Incentive
Government policy & initiatives 1 5 10 9 5 3.40 1.07 9
Increase of government project
using IBS 0 5 9 12 4 3.50 0.94 4
Directives, incentives, secure
projects 1 7 9 10 3 3.23 1.04 11
Reduce foreign workers 3 10 10 6 1 2.73 1.01 21
Quality expectation
Appearance : ability to customize
to suit client taste 5 10 6 8 1 2.70 1.15 22
Flexibility : allow system to be
used in different situations 1 6 13 9 1 3.10 0.88 15
In-service performance: durability
and maintenance requirement 0 10 12 8 0 2.93 0.78 18
Productivity
Quality control, Speed 0 4 8 11 7 3.70 0.99 1
Good design, Appearance 6 7 7 7 3 2.80 1.30 20
Product driver 1 8 11 8 2 3.07 0.98 16
Industry marketing strategies 1 4 9 12 4 3.47 1.01 5
Sustainability time 0 4 11 13 2 3.43 0.82 7
Technical
Getting the design process right 0 4 11 12 3 3.47 0.86 5
Certification of products, process
and people 0 7 8 4 11 3.60 1.19 2
Comparative robust 3 8 7 11 1 2.97 1.10 17
Financial
Attractiveness of potential
margins 0 4 10 12 4 3.53 0.90 3
Market security - life expectancy 1 3 11 12 3 3.43 0.94 7
Client perception of life
expectancy 2 6 10 7 5 3.23 1.17 11
Management
Establishing recognizable and
valued „brands‟ 2 11 8 5 4 2.93 1.17 18
Interfaces and their implications
across the whole supply chain 3 4 11 10 2 3.13 1.07 14
Environmentally friendly methods 1 7 9 12 1 3.17 0.95 13
Improve the image of the project
to the consumer 2 4 10 11 3 3.30 1.06 10
79
Table 4.5: Barriers in the implementation of IBS in construction industry
Average Index Rank
Funding 3.70 1
Product support 3.68 2
Certification 3.58 3
Sharing the Best Practices 3.53 4
Marketing 3.35 5
Table 4.6 listed out the main barriers of adopting IBS in construction industry.
According to the data analysis, the level of standardisation of IBS product is the most
influential barriers in the implementation of IBS. Adaptation of standardisation
requires a tremendous education and training effort.
Standardisation of building elements face resistance from construction
industry due to aesthetics reservation and economic reasons (Kampempool et al,
1986). Rahman et al (2006) says that the price of IBS is not competitive because lack
of support from government funded project, which ranked second in the barriers of
IBS implementation in this research.
Figure 4.8 listed out the five most influential barriers and five least influential
barriers. From the figure, it is to shown that the practical limitations are likely to
have more influences to the barriers of IBS implementation in the construction
industry. On the other hand, the indirect limitations are likely have less influences to
the barriers of IBS implementation in the construction industry.
80
Table 4.6: Barriers in the implementation of IBS in construction industry (in
categories)
Score
Frequency
Analysis Average
Index
Std
Dev Rank
1 2 3 4 5
Product support
Manufacturer not keen to proceed
with IBS concept 0 3 7 18 2 3.63 0.76 7
Material not fully exploited 1 2 13 11 3 3.43 0.90 14
Price 0 3 9 9 9 3.80 1.00 2
Requires information
sharing/database on tools &
machines
0 3 9 12 6 3.70 0.92 6
Level of standardisation 1 0 8 13 8 3.90 0.92 1
Compatibility and demand 0 6 6 12 6 3.60 1.04 9
Marketing
Product driver 0 8 12 7 3 3.17 0.95 20
Industry marketing strategies 2 3 14 6 5 3.30 1.09 18
Market Security 0 5 12 9 4 3.40 0.93 16
Educate the contractor available to
apply IBS 2 7 8 9 4 3.20 1.16 19
Market Demand 1 4 11 7 7 3.50 1.11 12
Funding
Obtaining finance 0 3 9 11 7 3.73 0.94 5
Initial cost and whole life 1 4 9 9 7 3.57 1.10 10
Government fund project 0 3 6 15 6 3.80 0.89 2
Certification
Lack of knowledge 0 4 10 13 3 3.50 0.86 12
Restrictive regulations 1 2 13 11 3 3.43 0.90 14
Technical limitation 0 3 8 11 8 3.80 0.96 2
Sharing the Best Practices
Expertise 0 2 12 11 5 3.63 0.85 7
User satisfaction 0 6 9 12 3 3.40 0.93 16
Skill shortage 0 2 11 15 2 3.57 0.73 10
81
Figure 4.8: Barriers in the implementation of IBS in construction industry
4.10 Ways to enhance implementation of IBS
Table 4.7 shows some of the possible ways to enhance implementation of
IBS. The respondent agreed that soft ways such as more incentives, proof cost and
time savings and supports from the governments are much better than hard ways
such as enforce IBS with law, strict regulations and bar cheap labour.
Hussein (2007) highlighted the costs of using IBS exceed the conventional
method of construction because of cheap immigrant labour. IBS design concept not
being taken into consideration in construction project. Designers did not design using
components as they not find the components in the market, whilst producers will not
produce components as they do not see design using components.
3.90
3.80 3.80 3.803.73
3.40 3.40
3.30
3.20 3.17
82
Table 4.7: Ways to enhance implementation of IBS
Score Frequency Analysis Average
index
Std
Dev Rank
1 2 3 4 5
Education awareness on IBS through
courses and seminars 1 3 5 17 4 3.67 0.96 7
Incentives from government to lower
costs of using IBS 1 1 8 9 11 3.93 1.05 1
Train workers in IBS knowledge 0 2 13 10 5 3.60 0.86 10
Standardise sizes and shapes of
components 0 3 6 13 8 3.87 0.94 4
Make architects design in accordance
to modular coordination (MC) 0 2 8 15 5 3.77 0.82 6
Proof of cost and time savings 0 2 8 10 10 3.93 0.94 1
Promote formation of other suppliers
to avoid monopoly 0 4 6 8 12 3.93 1.08 1
Promote designers to design in IBS 0 2 10 8 10 3.87 0.97 4
Enforce IBS with law 5 3 6 11 5 3.27 1.34 11
More research and development
initiative 1 5 6 10 8 3.63 1.16 8
Bar cheap labour 0 11 13 5 1 2.87 0.82 12
Increase IBS product / material range 1 0 11 15 3 3.63 0.81 8
Client expectation on the quality and design has led the industry to search for
more cost efficient, high quality and faster delivery systems. The current perception
is that traditionally built construction equates to building longevity. The government
need to act as the key driver to facilitate future development. One of the key benefits
of IBS is the ability to create differentiation in design at low cost. The system should
be successfully flexible to enable be spoke design, readily adaptable to suit
individual requirements.
4.11 Discussion
There are many complications in the implementing of IBS in the current state
of the construction industries because it involves many parties such as material
suppliers, labour, sub contractors and others will be affected. Although IBS has been
83
introduced for more than twenty years, however the construction still applies the
conventional which has been proven dirty, dangerous and wasteful. Therefore there
must be a strategy formulated to encourage the application of IBS in the local
construction industry. Followings are some discussion raised based on the analysis of
the study.
4.11.1 Reliance on manpower
Manpower is one of the most pressing challenges facing the Malaysian
construction industry as the “wet trade” construction approach at present relies
heavily on the availability of a large number of foreign workers. The “wet trade”
construction approach meant is the conventional cast in situ method. Apparently, the
construction industry in Malaysia is highly depends on the manpower especially
foreign labours. This is because the industry is more willing to employ unskilled
foreign labours with cheaper rates.
4.11.2 Avoid mismatch between the roadmap and readiness among contractors
and designers
This research pointed out that construction players are prepared in terms of
materials and labour to adapt IBS, but lack of technical knowledge and design
standards are the drawbacks. Lack of past experience in IBS and their professional is
lack of technical knowledge in IBS has generally discouraged IBS to take up (Hamid
et al., 2008). Rather than to say they are unwilling to change, they are unable to
change. Despite that various government plans, roadmaps, efforts such as IBS
Roadmap 2003-2010, CIMP 2006-2015 etc. to help on implementation of IBS, it is
also important to ensure that such efforts does not applies with the improper ways
among the contractors and designers.
84
4.11.3 Barriers of implementing IBS to various parties in construction
The research also pointed out the main barriers in adopting IBS are mainly
because of level of standardisation is insufficient, price, lack of support from
government funded projects and technical limitations.
To clients and contractors, unless there was necessary fast track projects such
as Tesco, Jusco project, IBS is often misinterpreted as high risk and expensive
solution (Kamarul, 2009). To designers which are the architects and consultants, lack
of knowledge among the IBS designers contributes to delays in design stage, for
example designers need extra time to produce details drawing to cater the usage of
IBS components in their design.
Another barrier is in dealing with established architects. There are the hardest
to convince to use IBS compared to smaller and less established architects. For them,
function must follow form. However in IBS, it is the other way around (IBS Modular
Sdn. Bhd, 2009)
4.11.4 The Ways of Implementing IBS
In this research, the results could be separated into „soft ways‟ and „hard
ways‟ to implement IBS in Malaysian construction industry. „Soft ways‟ such as
more incentives, proof cost and time savings and supports from the governments
tends to get more attention from the respondents. On the other hand, the „hard ways‟
such as enforce IBS with law, strict regulations and bar cheap labour can be
considered less efficient and might bring adverse effect to the construction industry.
CHAPTER 5
CONCLUSIONS AND RECOMMENDATIONS
5.1 Conclusions
This aim of the research is to examine and study the barriers in current
development of IBS in Malaysian construction industry. The purpose of this chapter
is to conclude all the findings derived from the study. All the three objectives set for
the research have been successfully achieved and the findings are summarized based
on the objectives of the research as follows:
5.1.1 Objective 1: To identify readiness of contractors and designers to adapt
IBS in their construction projects
This objective is to identify the readiness of the construction players to adapt
IBS in their construction project. From the findings, the level of overall readiness of
the construction players is at average level only. The readiness in terms of labour and
material to adopt IBS is higher than others factor. On the other hand the readiness in
terms of technical knowledge is very low. All the factors above are solely based on
the respondents‟ experiences since they are involved in the application of IBS in the
housing development projects. There are many other factors that can be considered
as more factors contribute to the more refined results in the analysis.
86
5.1.2 Objective 2: To determine barriers in the implementation of IBS in
Malaysian construction industry
The barriers of adopting IBS in Malaysian construction industry is mainly
due to lack of standardisation of IBS component, high price of IBS product, technical
limitation, lack of support from government funded projects to private sector. The
least most influential barriers are marketing strategies and product driver.
5.1.3 Objective 3: To identify ways to enhance the implementation of IBS in
the construction industry
The strategic management process does not end when the strategy has been
decided to pursue and therefore there must be a translation the strategy into action.
There must be a commitment and the strategy implementation effort by all the parties
involved. The success of the strategy formulation does not contribute to the
successful implementation of the strategy. Implementing strategies require such
action such as altering the laws, acts and legislations, training workers and others.
Soft ways such as more incentives, proof cost and time savings and supports
from the governments are some of the good way to further enhance the usage of IBS
in construction industry. However the hard ways such as enforce IBS with law, strict
regulations and bar cheap labour is considered least favourable by the respondents,
therefore is not efficient and could bring adverse effect to the industry.
5.2 Recommendations
This finding of the study gives an effective strategy to implement IBS in the
current state of the construction industry. Nonetheless, there are still some areas in
the IBS management that can be look into to conduct a research which can be look
into for further studies and further improvement can be made. The following
recommendation can be considered and used as reference for future study purposes.
87
1. Implementation plan of IBS by introducing policy and guidelines for
effective implementation
2. Investigation on design integration issues in IBS and conventional project
3. Continuous improvement that on the aspect of improving the strategy of
implementing IBS
4. Financial aspect as in the loan and the payback system to encourage IBS
investments in banking system
5. Critical Success Factors (CSF) in the implementation of IBS in public and
private projects in Malaysia
There are quite a numbers of survey related on IBS has been conducted
throughout Malaysia since 1996. The purpose of these surveys is to gather
information on implementation and application of IBS buildings Malaysia. IBS
features potential construction system for the future with emphasis on quality, higher
productivity and less labour intensive. Besides the aim of gradually reducing the
dependency on foreign labour 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. 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.
88
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APPENDIX – TECHNICAL PAPER
BARRIERS IN CURRENT DEVELOPMENT OF INDUSTRIALISED BUILDING SYSTEM
IN MALAYSIAN CONSTRUCTION INDUSTRY
Prof. Dr. Muhd Zaimi Abd Majid1, Kong Xi Haw
2
1 Professor, Faculty of Civil Engineering, Universiti Teknologi Malaysia
2 Postgraduate Student, Faculty of Civil Engineering, Universiti Teknologi Malaysia
ABSTRACT
Industrialised Building System (IBS) were introduced to Malaysia to solve issues associated
with dependencies of foreign workers, raising demand of affordable accommodations and
improving image, quality and productivity of construction industry. This research is to
highlights the current development of IBS in Malaysian construction industry and potential
challenges related to the implementation of IBS. The objectives of the research are to survey
the readiness of adapting IBS, determine barriers in the implementation of IBS and identify
ways to improve it. Questionnaires survey was conducted in order to achieve the objectives.
The data collected were tabulated using Microsoft Excel and analysed using average index
to validate the uncertainty from various literature findings. With these result, the barriers of
IBS implementation in Malaysia has been identified and discussed. According to this
research, technical limitation, lack of standardisation and price of IBS are the main barriers
in IBS implementation in Malaysia.
Keyword: Industrialised Building System (IBS); barriers; construction industry
1.0 INTRODUCTION
Malaysia is well known for its forward looking policies and strategies in the quest for global
participation in all facets of industry. Being a global player in construction requires serious efforts
towards adopting new systems and technologies par excellence with other developed and developing
nations. The success of these efforts will enable us to penetrate the global market and export our
professional and construction expertise while improving our own local development and management.
The construction industry plays a crucial role in the Government‟s efforts to stimulate domestic
economic activities and enhance growth. It is therefore important for the sector to continuously
undertake measures to increase efficiency, quality and productivity. Towards this end, the use of the
Industrialised Building Systems (IBS) is the right step in realising this objective.
IBS promises elevated levels of expertise throughout the industry, from manufacturers, installers,
engineers, planners, designers and developers. The benefits of IBS are numerous and far reaching.
Reduced construction time, better site management, reduced wastage are but a few of these benefits,
that will ultimately produce better products for the population. Undoubtedly, with better productivity,
quality and safety, IBS will contribute towards a better construction industry, as well as enhance the
global competitiveness of Malaysian builders.
1.1 PROBLEM STATEMENT
The construction industry constitutes an important element of Malaysian economy. Although it
account for only 2.8% of the gross domestic product (GDP) in fourth quarter of 2008, the industry is
crucial to national development as it has the direct effects to the economy of the country. The
construction industry also provides job opportunities for approximately 800,000 people (CIMP 2006-
2015). Nevertheless, the state of the local construction industry is not in line with future development
of Malaysia.
The main problem in the construction industry is because of dependency on foreign worker in
Malaysia (IBS Roadmap). The country is in a difficult situation where most of the foreign workers are
usually unskilled labour dominates in the construction industry. This lead to other problems such low
quality works, delays, wastages, social problems, diseases and etc. This discourage local workforce is
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to join the industry because of cheap foreign labour sources. Low awareness in occupational safety
and health has created a dirty, difficult, dangerous (3D) image to the construction industry. However,
the dependency on foreign workers by the Malaysian construction industry could be reduced by using
industrialised building systems (IBS). This is so because the prefabricated IBS components are
mechanically installed using cranes at sites using only a minimal number of manpower. Besides
requiring minimal labour, IBS offer better quality, increased productivity and faster completion; less
wastage with safer and cleaner construction sites. Through IBS, components are prefabricated off-site,
leaving the construction sites tidier and cleaner.
Despite all the advantages and support from the government, early effort to promote usage of IBS in
Malaysian construction industry is still very low compared to conventional methods. Although the
members of the industry are open to the idea, a major portion of the industry stakeholders are
indifferent. This is probably due to resistance towards change and insufficient information to support
feasibility of change. Local contractors are reluctant to switch to the usage of IBS because they are at
ease with the availability and relatively low cost of sourcing for unskilled foreign labour. The
adoption in Malaysia is more towards client-driven rather than consumer driven as compared to
developed countries.
1.2 AIM AND OBJECTIVE OF THE STUDY
This aim of the research is to examine and study the barriers in current development of IBS in
Malaysian construction industry. Specifically, to achieve the aim of this study, this research has the
following objectives:
1. Identify readiness of construction players to adapt IBS in their construction projects;
2. Determine barriers of adapting IBS in Malaysian construction industry; and
3. Identify ways to enhance the implementation of IBS in construction industry.
1.3 SCOPE AND SIGNIFICANCE OF THE STUDY
In order to achieve the objectives of this study, the scope of the research only focusing on the
development of construction industry in Malaysia. Concentrating on construction industry in Malaysia
could give a clearer sight of view of the overall development in local industry. Due to the extent that
IBS mainly involved steel structures and precast components, therefore the research are just restricted
to the building projects that uses traditional method and IBS only. The respondents are mainly
consisted of contractors, consultants (C&S engineers), developers, architects and quantity surveyors in
Malaysia.
Currently the main challenges in Malaysia‟s construction industry is lack of innovation and
motivation as the workforce is aging and shrinking as progressively fewer young enter the industry. If
this phenomenon continues to go on, the industry will swift to a very unhealthy condition, for example
rely heavily on foreign workers, lack of technology and modernisation in construction techniques.
Hence, the industrialisation of building construction method and the evolution of construction
technology are inevitable and plausible.
The first phase of successive implementation of IBS is the ability to find out the barriers that hinders
the development of IBS in Malaysia construction industry. This is very important because if the
barriers of implementation of IBS are identified, it enables for finding out solutions by focusing effort
to solve the problems.
2.0 METHODOLOGY
The purpose of the research is to study about the barriers in IBS implementation in the industry. In
order to achieve this, the information from previous researches and publication were compiled and a
questionnaire survey is conducted to identify the integrity of the results of previous researches. The
questionnaire design is based on literature readings and previous researches that focused on IBS in
construction industry.
The questionnaire forms were designed to be simple and which would require minimal filling-in time.
It consisted of several different parts which mainly includes a company profile, a survey on the
94
readiness of contractors and designers to adapt IBS in their construction projects, opinion survey
questions, suggestions and comments on the IBS usage.
The sampling of data is from April 2009 to May 2009. There were about 100 copies of questionnaires
were distributed to the targeted respondents consisted of architects, contractors, developers,
consultants and quantity surveyors. By the cut off date, the researcher managed to collect back 30
useable questionnaires from the respondents. This constitute of a sum of 35% response rate.
According to Fellows et al (1999), the normal expected useable response rate is ranging from 25% to
35%. Therefore, the total response received is considered sufficient for this research.
The data collected were analysed using average index and standard deviation of the data was
compared to highlight the trend of the inputs by the respondents. The result were tabulated
accordingly and presented in form of tables and figures with aid of Microsoft Excel.
3.0 DATA ANALYSIS
This chapter focuses on analyzing the results gathered from the respondents through interview and
questionnaire. Since time allocated for the distribution and collection of the questionnaire is very
limited, the distribution of questionnaire is limited to the respondents within the coverage of the
researcher only.
The data collected were converted into more meaningful, useful and informative formats that are in
the form of tables and figures. The data also were expressed according to the suitability of the analysis
itself. The questionnaires were distributed into different parts enables the analysis be done
systematically and reflects a logical result.
Table 3.1: Readiness of using IBS in building projects
Average Index Rank Std dev
Overall 2.90
0.96
Equipment (Components & machines) 2.87 5 1.04
Technical Knowledge 2.73 6 1.17
Labour 3.03 2 1.22
Material 3.07 1 1.17
Support (i.e. supplier, manufacturers etc) 2.97 3 1.16
Design Standard 2.90 4 1.16
From Table 3.1 shows that the score overall readiness of using IBS in building projects is not high,
where the average index from the feedback is 2.90 out of the maximum of 5.00 with standard
deviation of 0.96. The readiness of using IBS in building projects in terms of material have the highest
average index of 3.07. Meanwhile the readiness of using IBS is in terms of technical knowledge
having the lowest rank in this survey. This shows that what highlighted in Construction Industry
Master Plan (CIMP 2006-2015) is true where poor technical knowledge is one of the main reasons for
the low adoption of IBS in Malaysia. This lead to lack of integration caused IBS manufacturers
involved only after the design stage. This lack of integration among relevant players in design stage
has resultant in need for plan redesign and additional cost to be incurred if IBS is adopted. In this
research also pointed out where architects tend to have lower experiences with various types of IBS
than contractors and engineers.
Table 3.2: Barriers of adapting IBS in construction industry
Average Index Rank
Funding 3.70 1
Product support 3.68 2
Certification 3.58 3
Sharing the Best Practices 3.53 4
Marketing 3.35 5
For this research, the barriers of adapting IBS in construction industry were divided into five
categories as shown in Table 3.2. In these categories, the most identifiable category is funding which
have average index of 3.70. The least influential barriers is the marketing category which of 3.35.
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Table 3.3 listed out the main barriers of adopting IBS in construction industry. According to the data
analysis, the level of standardisation of IBS product is the most influential barriers in the
implementation of IBS. Adaptation of standardisation requires a tremendous education and training
effort. Standardisation of building elements face resistance from construction industry due to
aesthetics reservation and economic reasons (Kampempool et al, 1986). Rahman et al (2006) says that
the price of IBS is not competitive because lack of support from government funded project, which
ranked second in the barriers of IBS implementation in this research.
Table 3.3: Barriers of adapting IBS in construction industry
Barriers
Average
index
Std
Dev Rank
1. Product support
i. Manufacturer not keen to proceed with IBS concept 3.63 0.77 7
ii. Material not fully exploited 3.43 0.90 14
iii. Price 3.80 1.00 2
iv. Requires information sharing/database on tools & machines 3.70 0.92 6
v. Level of standardisation 3.90 0.92 1
vi. Compatibility and demand 3.60 1.00 9
2. Marketing
i. Product driver 3.17 1.00 20
ii. Industry marketing strategies 3.30 1.09 18
iii. Market Security 3.40 0.93 16
iv. Educate the contractor available to apply IBS 3.20 1.16 19
v. Market Demand 3.50 1.11 12
3. Funding
i. Obtaining finance 3.73 0.94 5
ii. Initial cost and whole life 3.57 1.10 10
iii. Government fund project 3.80 0.89 2
4. Certification
i. Lack of knowledge 3.50 0.86 12
ii. Restrictive regulations 3.43 0.90 14
iii. Technical limitation 3.80 1.00 2
5. Sharing the Best Practices
i. Expertise 3.63 0.85 7
ii. User satisfaction 3.40 0.93 16
iii. Skill shortage 3.57 0.73 10
Table 3.4 shows some of the possible ways to enhance implementation of IBS. The respondent agreed
that soft ways such as more incentives, proof cost and time savings and supports from the
governments are much better than hard ways such as enforce IBS with law, strict regulations and bar
cheap labour.
Table 3.4: Ways to enhance implementation of IBS
Average
Index
Std
Dev Rank
Education awareness on IBS through courses and seminars 3.67 0.96 4
Incentives from government to lower costs of using IBS 3.93 1.05 1
Train workers in IBS knowledge 3.60 0.86 6
Standardise sizes and shapes of components 3.87 0.94 2
Make architects design in accordance to modular coordination (MC) 3.77 0.82 3
Proof of cost and time savings 3.93 0.94 1
Promote formation of other suppliers to avoid monopoly 3.93 1.08 1
Promote designers to design in IBS 3.87 0.97 2
Enforce IBS with law 3.27 1.34 7
More research and development initiative 3.63 1.16 5
Bar cheap labour 2.87 0.82 8
Increase IBS product / material range 3.63 0.81 5
96
Hussein (2007) highlighted the costs of using IBS exceed the conventional method of construction
given the ease of securing cheap immigrant labour. IBS design concept is not being taken into
consideration at the onset of the project. Designers will not design using components as they not find
the components in the market, whilst producers will not produce components as they do not see design
using components.
Client expectation on the quality and design has led the industry to search for more cost efficient, high
quality and faster delivery systems. The current perception is that traditionally built construction
equates to building longevity. The government need to act as the key driver to facilitate future
development. A key benefit of IBS is the ability to create differentiation in design at low cost. The
system must be successfully flexible to enable be spoke design, readily adaptable to suit individual
requirements.
4.0 DISCUSSION
There are many complications in the implementing of IBS in the current state of the construction
industries because it involves many parties such as material suppliers, labour, sub contractors and
others will be affected. The construction industry still applies the conventional which has been proven
dirty, dangerous and wasteful. Therefore there must be a strategy formulated to encourage the
application of IBS in the local construction industry.
Every industry needs better productivity, quality and safety to be globally competitive; while the
factors affected the productivity of the construction industry are include weather, temperature,
fabrication errors, and material deliveries (Lim, 2006). Durability of construction and materials are
ability to sustain harsh climatic & seismic loading. IBS offers a superior and consistent high quality
finished product. It is produced at factory with better quality control. Construction technique in which
components are manufactured in a factory, on or off site, positioned and assembled into a structure
with minimal additional site works.
Manpower is one of the most pressing challenges facing the Malaysian construction industry as the
wet trade construction approach at present relies heavily on the availability of a large number of
foreign workers. The wet trade construction approach meant is the conventional cast in situ method.
Apparently, the construction industry in Malaysia is highly depends on the manpower especially
foreign labours. This is because the industry is more willing to employ unskilled foreign labours with
cheaper rates.
Initial cost have attractiveness of potential margins by affected by industry capacity, IBS being
undertaken by traditional construction firms, lack of global or international approach, and poor
perception of performance from the past. Precise cost knowledge needed for comparisons both
„traditional‟ and „new‟. Misconception due to lack of knowledge of design philosophy and the special
characteristic & rules associated with precast design and construction. The limited knowledge leads to
resistance to change and low adoption of IBS. Delivery system of project is not friendly enough is one
the barriers of IBS adoption. Delivery of materials may influence the labour productivity adversely.
Delay in the material deliveries and time needed to unload material reduces the labour productivity.
Since the application of IBS involves many parties such as manufacturers, installer, transporter and
various government bodies concerned. Therefore there should be a responsible 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. Furthermore, besides
giving levy to the contractors, the government also can offer flexible financing and tax reduction to
manufacturers and constructor as to encourage the IBS implementation in the construction.
The strategic management process does not end when the strategy has been decided to pursue and
therefore there must be a translation the strategy into action. There must be a commitment and the
strategy implementation effort by all the parties involved. The success of the strategy formulation
does not contribute to the successful implementation of the strategy. Implementing strategies require
such action such as altering the laws, acts and legislations, training workers and others.
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5.0 CONCLUSION
This aim of the research is to examine and study the barriers in current development of IBS in
Malaysian construction industry. The purpose of this chapter is to conclude all the findings derived
from the study. All the three objectives have been successfully achieved and the findings are
summarized based on the objectives of the research as follows:
Objective 1: Identify readiness of construction players to adapt IBS in their construction projects
This objective is to identify the readiness of the construction players to adapt IBS in their construction
project. From the findings, the level of overall readiness of the construction players is at average level
only. The readiness in terms of labour and material to adopt IBS is higher than others factor. On the
other hand the readiness in terms of technical knowledge is very low. All the factors above are solely
based on the respondents‟ experiences since they are involved in the application of IBS in the housing
development projects. There are many other factors that can be considered as more factors will
contributes to more refined results in the analysis.
Objective 2: Determine barriers of adapting IBS in Malaysian construction industry
The barriers of adopting IBS in Malaysian construction industry is mainly due to standardisation of
IBS component, price of IBS product, technical limitation, lack of support from government funded
projects to private sector. The least most influential barriers are marketing strategies and product
driver.
Objective 3: Identify ways to enhance the implementation of IBS in construction industry
Soft ways such as more incentives, proof cost and time savings and supports from the governments
are some of the good way to further enhance the usage of IBS in construction industry. However the
hard ways such as enforce IBS with law, strict regulations and bar cheap labour is considered least
favourable by the respondents, therefore is not efficient and could bring adverse effect to the industry.
This finding of the study gives an effective strategy to implement IBS in the current state of the
construction industry. Nonetheless, there are still some areas in the IBS management that can be look
into to conduct a research which can be look into for further studies and further improvement can be
made. The following recommendation can be considered and used as reference for future study
purposes.
1. Implementation plan of IBS by introducing policy and guidelines for effective
implementation
2. Investigation on design integration issues in IBS and conventional project
3. Continuous improvement that on the aspect of improving the strategy of implementing IBS
4. Financial aspect as in the loan and the payback system to encourage IBS investments in
banking system
5. Critical Success Factors (CSF) in the implementation of IBS in public and private projects in
Malaysia
There are quite a numbers of survey related on IBS has been conducted throughout Malaysia since
1996. The purpose of these surveys is to gather information on implementation and application of IBS
buildings Malaysia. IBS features potential construction system for the future with emphasis on quality,
higher productivity and less labour intensive. Besides the aim of gradually reducing the dependency
on foreign labour 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. 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.
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