Prof. Ir. Dr. Zuhairi Abd. HamidExecutive Director

Construction Research Institute of Malaysia (CREAM)CIDB MALAYSIA

IBS Towards Sustainable Construction:Examining the role and contribution of IBS to green construction and

sustainability initiatives

13 July 2010

Key Milestones from 1999 to 2010

2004 2005 2006 2007 2008 2009 20152003

MS 1064: Modular Coordination as Guideline for Building Design

Joint effort by CIDB, SIRIM and professional bodies

IBS Roadmap 2003-2010

Manual for IBS Content Scoring Published

Circular issued on IBS by Treasury on 25 July 2005

“Encourage”

Follow-up Treasury Circular on IBS issued on 31 Oct 2008

“Mandate”

1999

IBS Strategic

Plan 1999

IBS Roadmap Review 2008-2010

2010

Malaysia IBS International Exhibition ‘06

approved by the Cabinet

Construction Industry Master Plan2006-2015

Malaysia IBS International Exhibition ‘09

IBS Roadmap

2011-2015

2001

IBS Thrust in the Construction Industry Master Plan

7 Strategic Thrusts under CIMP

Sou rce : Con stru ct io n Indu stry Mast er Plan, 20 06 -20 15

Recommendation 5.1 Continuously innovate construction processes and techniques

Executed Through IBS Roadmap

Recommendation 5.1.1Encourage the adoption of new construction techniques and technologies

Recommendation 5.1.2Encourage the development of manpower to support adoption of I BS/MC

Recommendation 5.1.3Continue to deve lop materials to support a doption of IBS

Recommendation 5.1.4Continue to enhance management processes and methods to encourage adoption of IBS

Recommenda tion 5.1.5Provide monetary (economic and fina ncial) support to encourage adoption of IBS

Recommendation 5.1.6Marke t and promote IBS/MC

Recommendation 5.2 Stimulate R&D activities through resource-pooling initiative amongst key pla yers and provision of R&D infra structure

Recommendation 5.2.1Leverage on CIDB ’s CREAM to spur construction R&D

Recommendation 5.2.2Act as facilitator between the industry, a cademia , and the government

Recommendation 5.2.3Collaborate with other Centres of Research Exce lle nce for construction R&D

Re commendation 5.2.4Esta blish funding require ments and sources of funding

Integrate the construction industry value chain to enhance productivity and efficiency

Strengthen the construction industry ima ge

Strive for the highest standard of qua lity, occupa tional safety and health, and environmental practices

2

3

Develop human resource capabilities and ca pacities in the construction industry

Innovate through re search and development and adopt new construction me thods

Leverage on information and communication technology in the construction industry

4

5

6

Bene fit from globalisationincluding the export of construction products and service s

7

1

Specific mention of IBS in CIM

P

7 Strategic Thrusts under CIMP

Sou rce : Con stru ct io n Indu stry Mast er Plan, 20 06 -20 15

Recommendation 5.1 Continuously innovate construction processes and techniques

Executed Through IBS Roadmap

Recommendation 5.1.1Encourage the adoption of new construction techniques and technologies

Recommendation 5.1.2Encourage the development of manpower to support adoption of I BS/MC

Recommendation 5.1.3Continue to deve lop materials to support a doption of IBS

Recommendation 5.1.4Continue to enhance management processes and methods to encourage adoption of IBS

Recommenda tion 5.1.5Provide monetary (economic and fina ncial) support to encourage adoption of IBS

Recommendation 5.1.6Marke t and promote IBS/MC

Recommendation 5.2 Stimulate R&D activities through resource-pooling initiative amongst key pla yers and provision of R&D infra structure

Recommendation 5.2.1Leverage on CIDB ’s CREAM to spur construction R&D

Recommendation 5.2.2Act as facilitator between the industry, a cademia , and the government

Recommendation 5.2.3Collaborate with other Centres of Research Exce lle nce for construction R&D

Re commendation 5.2.4Esta blish funding require ments and sources of funding

Integrate the construction industry value chain to enhance productivity and efficiency

Strengthen the construction industry ima ge

Strive for the highest standard of qua lity, occupa tional safety and health, and environmental practices

2

3

Develop human resource capabilities and ca pacities in the construction industry

Innovate through re search and development and adopt new construction me thods

Leverage on information and communication technology in the construction industry

4

5

6

Bene fit from globalisationincluding the export of construction products and service s

7

1

Specific mention of IBS in CIM

P

The importance of IBS was emphasised in the Construction Industry Master Plan (“CIMP”) in 2006. Introduction of new construction methods such as IBS was under Strategic Thrust #5. All the seven strategic thrusts are expected to work in a holistic manner to leap frog the development of the construction industry. According to the CIMP, manpower development, research on materials, monetary (economic and financial), management processes and promotions are required to increase the usage of IBS.

Towards an Open Building System

Open Building System

Structural

Systems

Wall

Systems

Other

Systems

Groups of IBS ComponentsType 1 Pre-cast Concrete Framing, Panel and Box SystemsPre-cast columns, beams, slabs, 3-D components (balconies, staircases, toilets, lift chambers), permanent concrete formwork etc

Type 2 Steel Formwork SystemsTunnel forms, beams and columns moulding forms, permanent steel formworks (metal decks) etc

Type 3 Steel Framing SystemsSteel beams and columns, portal frames, roof trusses etc

Type 4 Prefabricated Timber Framing SystemsTimber frames, roof trusses etc

Type 5 Block Work Systems

Under the Open Building System concept, a building is made up of a series of systems, sub-systems and groups of input components. A crucial objective of moving towards an open building system is the inter-changeability factor. An open system ensures that components or sub-systems are interchangeable and easily replaceable.

Potential cost reduction of industrialized construction (CIB, 2010)

The value creation in industrialised construction (CIB, 2010).

To ensure that by using IBS, completion time of a building is speedier, more predictable and well-managed.

To have a ready pool of competent IBS professionals and workers throughout the entire project life-cycle: from design, manufacture, build to maintain.

To create a financially sustainable IBS industry that balances user affordability and manufacturer viability

Good quality designs, components and buildings are the desired outcome of IBS. Aesthetics should be promoted through innovation.

Source : BinaFikir analysis

Competency & Productivity

Financial Sustainability

Delivery Efficiency

Quality

MISSION: TO PROVIDE A QUALITY, EFFICIENT, COMPETENT & SUSTAINABLE IBS INDUSTRY THAT CONTRIBUTES TO THE COMPETITIVENESS OF MALAYSIA’S CONSTRUCTION SECTOR

Policy objectives are the high level intended outcomes of implementing IBS. To remain focused, it was narrowed down to four policy objectives i.e. quality, efficient, competent and sustainable. A sustainable IBS industry will contribute to the competitiveness of the construction industry.

IBS Roadmap 2011 - 2015

Source : BinaFikir analysis

High Quality Buildings and Timely Completion

Sustainable policy & political will

Integration of IBS into Construction Industry Value Chain

Standardisation must be Holistic and Comprehensive (Policy, Administrative and Legal)

IBS People Development

Less Labour Intensive

Financially Sustainable

Objective

Pillar

Foundation

THE HOUSE OF IBS

IncentivesGreen Technology

Quality Mindset in Award of Contract

R&D

What is sustainability and why is it important?The United Nations Brundtland Commission Report (1987) defined sustainable development and urged the world to take note: “Sustainable development is that which meets the needs of the present without compromising the ability of future generations to meet their own needs.” A growing global population is straining the finite resources available onthe planet. Sustainability seeks to balance the economic, social, and environmental impacts, recognizing that population growth will continue. Sustainable development brings this evaluation to the design and construction industries, which have significant potential to reduce the negative impact of human activities on the environment.

History of Sustainability?• Energy efficiency gained importance during the

1970’s oil crisis• Recycling efforts in the 1970’s became

commonplace and came to the attention of the building industry

• 1980’s the “sick building syndrome” emerged • Projects in water scarce areas began to focus on

water conservation• Early green designs • 1990’s integration of all factors would result in a

“high performance” building

Dimensions of SustainabilityEconomic Vs. Social Vs. Ecological Developments

BalancedSustainability

PuristicGreen

ConservationismSocial

EconomicDevelopment

Imperative:• Be aware of thecapability forrecovery

• Keep resources and ecological systems

• Reduce waste

Imperative:• achieve human needs

• spread wealth• Increase localautarchy

• Assure securityand liability

Imperative:• Grow econimcally• Stay profitable• Expand markets• Unfold costs

Holistic Structure in Sustainable Construction

What is Green Technology

Green Technology &

Opportunities

Energy & Technology

Solar powerWind powerEnergy Storage & Transportation

BuildingDesignConstructionBuilding Materials

Public Sector & Utilities

Planning EnergyWater

(Source: Developed from Lockwood, 2007)

HoweverSustainable issues in construction industry

• Influx of foreign workers (600,000 over 800,000 total workforce). Social and economy impact??

• Environmental sustainability ???

• 30-40 % of natural resources were exploited by building industry

• 50 % energy used for cooling and heating in buildings

• Almost 40% of the world’s consumption of materials converts to the built environment

• 30% of energy use is due to housing

Challenges of Sustainable Construction

• The first one is the “circle of blame” among the project participants. Service providers namely the contractors and consultants; said clients do not ask for sustainability (Baldock, 2000). The design team persists in the old ways and is reluctant to make the first move to new territory. Clients, on the other hand, are afraid that the building will cost more and take a longer time (Bordass, 2000). They also expect the service providers to take the lead in improving their services (BusinessVantage, 2002).

• Sustainability is treated as a discrete problem with an isolatedsolution, which creates difficulties in blending it into the construction process (Griffith, 1996; Barrett et al., 1998). Introduction of sustainability issues at later than the design stage causes changes in plan or design, which would incur more costs than savings (Connaughton & Green, 1996; Norton & McElligott, 1995)

• Ofori (1998) stated that construction faced difficulties in providing guidance for good environmental practice in construction. Proper guidance needs to be formed to resolve this matter.

• Change resistance is viewed as involving change in individual values, whether at personal, corporate, or collective level. Although the values are generally at the right place, the problem is to enact them.

Is precast concrete a green building material?

Precast concrete contributes to green building practices in significant ways. The low water-cement ratios possible with precast concrete -0.36 to 0.38- mean it can be extremely durable. The thermal mass of concrete allows shifting of heating and cooling loads in a structure to help reduce mechanical-system requirements. Because precast concrete is factory-made, there is little waste created in the plant (most plants employ exact-batching technologies) and it reduces construction waste and debris on site, reducing construction IAQ concerns. The load-carrying capacities, optimized cross sections, and long spans possible with precast concrete members help eliminate redundant members, and concrete readily accommodates recycled content.

Source:Midway-Atlantic Precast Association

How does precast concrete contribute to the underlying sustainability concept of “Reduce, Reuse, Recycle”?

By reducing the amount of materials and the toxicity of waste materials.Precast concrete can be designed to optimize (lessen) the amount of concrete used in a structure or element

As one example, the use of carbon-fiber reinforcement or insulation can reduce:

• Amount of concrete needed in a precast concrete panel• Weight of a precast concrete panel• Transportation cost of precast concrete panel• Amount of energy used to erect a precast concrete panel

Precast concrete generates low amounts of waste with low toxicity

• 2% of the concrete at a precast plant is waste• 95% of the waste is used to manufacture new panels• By reusing products and containers and repairing what can be reused• Precast concrete panels can be reused when buildings are expanded or dismantled• Concrete pieces from demolished structures can be reused to protect shorelines• Wood or fiberglass formwork used to make precast concrete products is generally reused 40 or more

times• Concrete and steel have practically unlimited service lives• By recycling as much as possible, including buying products with recycled content• Industrial wastes (fly ash, slag, and silica fume) can be used as partial replacements for cement• Wood and steel forms are recycled when they become worn or obsolete• Virtually all reinforcing steel is made from recycled steel• Insulation contains partially recycled material• Concrete in most urban areas is recycled as fill or road base Source:Midway-Atlantic Precast Association

Potential Roles of IBS in Green Construction and Sustainability

Potential Role of IBS in

Green Construction

& Sustainability

Sustainabilityfrom

Controlled Production Environment

IBS & Waste Reduction

IBS &Building Materials

IBS & Logistics

IBS & Economic

Sustainability

• IBS offers a controlled manufacturing environment with the ability to reach difficult nooks and corners, which are often inaccessible in regular in-situ construction.

• With the availability of production tools, and permanent jigs and fixtures, it is easier to control the workmanship of construction, ensuring a tighter construction resulting in lot lesser energy losses due to leakages (thermal leakage)

Sustainability and Control Production in IBS

IBS & Waste Reduction

• IBS traditionally has been known to minimize waste, with the ability to reuse material from one module or product into another, the sustainability agenda is supported through its use.

• However, several aspects of planning both in terms of materials management and production management have to be monitored in order to achieve the waste minimization benefits promised by IBS.

Sustainability and Control Production in IBS continued

IBS & Building Material• Several pre-fabricated technologies such as

Structural Insulated Panels (SIPS) etc offer great potential in terms of fabrication of more energy efficient buildings

• However, if appropriate process control and planning are not implemented these potential benefits could be lost due to expensive on-site assembly processes.

• Therefore, it is important that the advent of new technologies should be accompanied by proper process design for on-site assembly.

Sustainability and Control Production inIBS continued

IBS & Logistic Issues

• Some estimates recently have put the amount of environmental impact from material transportation activities to be one-third of total environmental impact on the entire construction process.

• IBS offers another benefit, and that is the ability to order in large quantities thus reducing the number of trips to be taken. Despite this potential benefit, it is important that a detailed material transportation and logistics plan be put in place

Sustainability and Control Production in IBS continued

Building Reuse

• Precast concrete members are unique in that they can be dis-assembled. Precast concrete walls can be used for building expansion or fire walls.

• Crushed concrete can be used as aggregate or can be used as base material for roads, sidewalks or slabs.

Re-usable forms• Steel forms are

used to cast structural precast products. These forms have a long life span providing thousands of reuses.

• Specialty shaped forms are stored for future use.

Exact Batching Technologies = little waste at plant

Controlled Environment

Qualified and trained personnel minimize waste every day

Recycled Materials

• Use of fly ash, slag or silica fume is commonplace –as substitute for cement

• Reinforcement and connection hardware are made from recycled steel

• Substitution aggregates

Wall Assembly Performance

• Energy transfer is minimized by wall design:

– Add insulation– Add mass – Minimize thermal bridging– Minimize infiltration & exfiltration– Control moisture

Heat EnergyHeat Energy

WarmAir

CoolAir

Green Building Index (GBI)

• Developed by Association of Consulting Engineers Malaysia (ACEM) and Pertubuhan Arkitek Malaysia (PAM) to promote sustainability in Built Environment

• Six (6) key criteria including energy efficiency, indoor environment quality, sustainable site planning, material and resources, water efficiency and innovation

GBI (Malaysian Green Building Index)

GBI (Residential) & IBS• SM 3: Sustainable Site Planning and Management - Encourage IBS and reduce on-

site construction. Reduce material wastage and construction wastage to landfill sites. Reduce the polluting effects of construction and from workers during construction (IBS > 50 = 1 points, IBS > 70 = 2 points)

• EQ 4: Good Quality Construction - Encourage and recognise good quality construction – first time right – that does not require re-work that wastes materials and labour (> 70% CIDB’s QLASSIC points) (1 point)

• MR 2: Material Reuse and Selection - Reuse building materials and products in order to reduce demand for virgin materials and to reduce waste, thereby reducing impacts associated with the extraction and processing of virgin resources. Integrate building design and its buildability, with careful selection of building materials in relation with embodied energy and durability of the materials to lower carbon content and better building life cycle (2 points)

• MR 3: Construction Waste Management - If project uses high level of prefabrication with IBS score > 70, (1 point for every 10% increase in prefabrication up to a maximum of 2 points)

• IN 1: Innovation in Design and Environmental Design Initiative –Innovative use of building features to passively cool the building (not an exclusive item) (up to 5 points)

Objectives (CREAM)1. To investigate the main issues in green construction and sustainability

2. To ascertain and document the roles and contributions of IBS

3. To document the major drivers and challenges associated with implementing green construction and sustainability

4. To explore cases where green construction and sustainability issues are integral to IBS

5. To determine and document the main factors (Critical Success Factors)

6. To develop and validate a framework for better understanding

7. To disseminate findings widely through industry and academic communication

Research Agenda for Sustainability and Green

Source: VTT Finland

MANUFACTURING IN CONSTRUCTION

MANUFACTURING

DESIGN

CONSTRUCTION

Manufacturing Construction

• Product Based• Long Term Supply

Chain Relationships• Profit in Volumes of

Similar Products• Higher Mechanisation

Due to Repeatability of Process

• Project Based• Short Term Project

Based Supply Chains• Profit from

Customized Solutions• Very Manual

INTRODUCTION

• Makmal Kerja Raya Malaysia is funded by the Ministry of Works and CIDB

• Managed by Construction Research Institute of Malaysia (CREAM)

• Development begin early 2008• CREAM move in to new premise in

March 2009• Fully operational scheduled by August

2009

Facilities ProvidedThe main facilities and testing equipments provided are as follows;

• Reaction Floor - 15 m wide by 26 m long• Reaction Wall - 6 m long by 6 m high• 2000 kN Universal Testing Machine• 200 kN Dynamic Testing Machine• 300 kN Dynamic Actuator• 500 kN Static Actuator• 2000 kN Static Actuator• Double Portal Frame (static actuator)• Single Portal Frame (dynamic actuator)• 3000 kN Compression Machine• 5000 kN Compression Machine• Adjustable pre-stressing bed • Overhead lifting crane - Combined capacity of 40 tonne

FACILITIES

REACTION FLOOR • Dimension 15m x 26m• 10,000 kN maximum static load

applied • 1400 number of anchoring points• 500 mm distance centre to centre

between points• Max working capacity of point

– 400 kN vertical– 150 kN horizontal

• High stiffness design, 1mm deflection tolerance for 300 ton static load

REACTION WALL

• Dimension 6m x 6m x 1m• 20,000 kNm wall capacity• Max working capacity of point

– 300 kN horizontal– 100 kN shear

The Way Forward• Assessment tool is another way to identify

present performance which will in turn be used to instigate improvement. In Malaysia, effort has been forwarded by PAM in collaboration with ACEM to produce an assessment method called GBI Malaysia. Having this GBI Malaysia is a positive move to propel the industry towards sustainable and environmental responsibility. And effective implementation is vital to ensure the success of these two in shaping the industry in the future

The Way Forward• To incorporate and applies innovation in

construction such in the form of Industrialised Building System (IBS). The fundamental idea of IBS is to move on-site work to more controlled environment in a manufacturing floor. IBS promote sustainability from controlled production environment minimisation of waste generation effective usage of energy, efficient building materials, effective logistic and long term economic stability which can contribute to better investment in environment technologies.

The Way Forward• Research and innovation is the best way to improve and

expand knowledge and technology. Government agencies like CIDB and Ministry of Science, Technology & Innovation (MOSTI) should increase grant allocation on the research area related to sustainable and green construction.

• The introduction and adoption of whole life cycle costing (WLCC) and green procurement in construction industry.

• Establishment of eco-labelling scheme for construction materials that incorporates the need of GBI Malaysia.

• Benchmarking and technology transfer of best practices from developed countries in implementing sustainable and green construction agenda.

FOR FURTHER INFORMATION:

CONSTRUCTION RESEARCH INSTITUTE OF MALAYSIA

MAKMAL KERJA RAYA MALAYSIA

PUSAT IBS, BLOK E, TINGKAT 1

JALAN CHAN SOW LIN

55200 KUALA LUMPUR

MALAYSIA

60-3-9281 0800

60-3-9282 4800

http://www.cream.com.my

THANK YOU

“Make CREAM your partner in R&D”