INTRODUCTION OF IBS IN CONSTRUCTION INDUSTRY

Assoc Prof Dr Taksiah A.Majid School of Civil Engineering Universiti Sains Malaysia Politeknik Ungku Omar, 25 Nov 2010
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CONTENT OF PRESENTATION

TOPIC 1 : IMPLEMENTATION OF IBS IN MALAYSIA & CHALLENGE IN THE IBS INDUSTRY TOPIC 2 : INTRODUCTION TO MODULAR COORDINATION TOPIC 3 : BUILDIBILITY OF DESIGN
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TOPIC 1 :

IMPLEMENTATION OF IBS IN MALAYSIA & CHALLENGE IN THE IBS INDUSTRY

Presentation Outline For Topic 1

1. IBS in Malaysia 2. Government Policies on IBS 3. Current Status & Challenges 4. The IBS Centre

IBS IN MALAYSIA

WHAT IS IBS?

Definition of Industrialized Building Systems (IBS)

A construction technique in which components are manufactured in a controlled environment (on or off site), transported, positioned and assembled into a structure with minimal additional site works
Comparison: Offsite construction UK Modern Method of Construction - MMC
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TYPE 1: PRECAST CONCRETE FRAME, PANEL & BOX SYSTEMS

PC columns, beams, slabs, 3D-components (balconies, staircases, toilets, lift chambers, box girders, etc)

TYPE 2: STEEL FORMWORK SYSTEMS

Tunnel forms, beams and column moulding forms, permanent steel formworks (metal decks), etc.

TYPE 3 : STEEL FRAME SYSTEMS

Steel beams and columns, portal frames,roof trusses, etc

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TYPE 4: PREFABRICATED TIMBER FRAME SYSTEMS

Timber frames, pre-fab timber roof trusses, etc.

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TYPE 5 : BLOCKWORK SYSTEMS

Interlocking concrete masonry unit (CMU), lightweight concrete blocks, etc.

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TYPE 6 : INNOVATIVE PRODUCT SYSTEMS

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GOVERNMENT POLICIES IN IBS

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IBS Roadmap 2003-2010 & 3 Main Objectives

Reduction in the usage of Foreign Labour. Quality, productivity, safety and competitiveness in the construction sector. To induce new socio-economic activities through the creation of IBS components based industry based on Open System.

Approved by the Federal Cabinet Ministers on 29 October 2003

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Treasury Circular on IBS - 31 Oktober 2008

To all Federal Ministries, Head of Departments, State Governments, Regulatory bodies, and Local Authorities. Adoption of Open System methodology through the use of Modular Coordination, MS 1064. Requirement of 70% IBS content in Government projects. National IBS Sectretariat as the Coordinator through the Ministry of Works. Implementation Coordination Unit of Prime Ministers Department as the monitoring unit. IBS Centre as the One Stop Centre.

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Monitoring Structure on Government IBS Projects Implementation

FEDERAL MINISTERS
CABINET COMMITTEE ON INVESTMENT AND INFRASTRUCTURE IBS MAIN COMMITTEE Chairman : Chief Secretary Members: Centralised Agencies & Ministries Secretariat : Implementation Coord. Unit Scope : Coordination on IBS Policies

NATIONAL IBS SECRETARIAT Chairman : Ministry of Works Members : Centralised Agencies & Ministries Secretariat: Ministry of Works Scope : IBS Projects Implementation

IBS ENFORCEMENT MONITORING COMMITTEE Chairman: Implementation Coord. Unit Members : Public Works Dept., ICU & Treasury Sekretariat : Treasury Skop : Monitoring the Enforcement of Government Circular on IBS

IBS COMPONENTS MGMT COMMITTEE Chairman : CIDB Malaysia Members: Representatives of Construction Industry Secretariat: CIDB Malaysia Scope : Coordination at industry level

IBS TECHNICAL COMMITTEE Chairman : Public Works Dept Members: Implementation Agencies & Development Division of Ministries. Secretariat: Public Works Dept Scope : Coordination on Technical & Projects

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Key Milestones from 1999 to 2010

IBS Roadmap 2003-2010 approved by the Cabinet IBS Strategic Plan 1999 Construction Industry Master Plan 2006-2015 Malaysia IBS International Exhibition 06 IBS Roadmap Review 2008-2010 Malaysia IBS International Exhibition 09

1999 2001

2003 2004 2005 2006 2007 2008 2009 2010

Manual for IBS Content Scoring Published Circular issued on IBS by Treasury on 25 July 2005 Follow-up Treasury Circular on IBS issued on 31 Oct 2008

2015

MS 1064: Modular Coordination as Guideline for Building Design Joint effort by CIDB, SIRIM and professional bodies

IBS Roadmap 2011-2015

Encourage

Mandate
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CURRENT STATUS AND CHANLLENGES

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Lessons drawn from Singapore : how to successfully promote IBS by linking to BUILDABILITY
Singapore
Purpose
The purpose of buildability is to ensure that the impact of the design and details on construction are recognized at the conceptual planning stage. This will minimize any problems that will be experienced at later stages of construction, thus reaping the maximum benefits from buildability in terms of time, cost and quality The design-build approach offers an opportunity to integrate the interests of design and construction together. Contractors are involved with design development and maintain close co-operation with the design team A responsibility system for architects is proposed. Architects can concurrently work as an engineer to supervise the construction process, and they can be in charge for the final acceptance of construction projects. The proposal ensures that the design is implemented correctly and the problems on site are revealed to the architects New projects (including additions and alterations to existing buildings) with a gross floor area (GFA) equal to or greater than 2,000m2 falls within the legislative requirements. The minimum score requirement is approximately about 60

Best Practices

Integration of design - build Responsibility of architects

Coverage Approval to build Clear path

Minimum buildability scores must be complied with by all property developments before building plans approvals are given by the relevant building authorities. Legislation was passed in 2001 to make buildability compulsory The average buildability scores for various categories of new building works have increased over the years and constantly communicated to the industry. Staged incremental of the score is clearly communicated. This help the manufacturing base to expand accordingly. 20

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IBS Component manufacturing

# Name Head office Number of Factories
P rec as t C olumn 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 MTD ACPI Engineering Berhad Hume Concrete Marketing Sdn Bhd HL- Manufacturing Industries Sdn Bhd Eastern Pretech (M) Sdn Bhd Precast Product Sdn Bhd Setia Precast Sdn Bhd SCID Concrete Manufacturing Sdn Bhd Sunway Precast Industries Sdn Bhd CMS Concrete Products Sdn Bhd OKA Concrete Industries Sdn Bhd E.V. Oilfield Supply And Services Sdn Bhd Binaan Desjaya Sdn Bhd Baktian Sdn Bhd CSR Building Materials (M) Sdn Bhd P Slabs (M) Sdn Bhd IBS Prestress Technology Sdn Bhd Ezidek (M) Sdn Bhd PJDCP Malta Sdn Bhd HC Precast System Sdn Bhd Sunway Cavity Wall Panel Sdn Bhd Jitra Engineering Sdn Bhd Selangor Selangor Johor KL NS Selangor Sarawak Selangor Sarawak Perak Melaka Pahang KL Selangor KL Terengganu Melaka KL Selangor Selangor KL 6 5 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1

Precast Concrete Plants

PRODUCTS
P rec as t B eam P rec as t S lab P c Wall/ P anel P rec as t S tairc as e S'gor Johor Perak N. S.

FACTORY LOCATION
Pahang T'ganu

Malacca

Kedah

P. Pinang

Sabah

Sarawak

1 1 1 1

1 1 1

1 1

1
1 1 1

TY P E 1

1
1

1 1
1

1
1

1
1

31

TOTAL

The 21 manufacturers owned a total of 31 plants between them. The players with the most number of plants are MTD ACPI (6), Hume Concrete (5) and Sunway Cavity (2). The remaining 18 are single plant operators. The location of the plants is very important in determining the market accessibility seems well spread out with concentration in the state of Selangor (8), Johor (5) and Negeri Sembilan (4). There are currently no 21 plants in Kelantan and Perlis.

IBS Component manufacturing

Innovative, Panel and Block System Plants
FACTORY LOCATION
Perak T'ganu

# Name
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Cycleworld Corporation Sdn Bhd Boral Plasterboard (Malaysia) Sdn Bhd Saint-Gobain Construction Products (M) Sdn Bhd HLE Precast Sdn Bhd EVG Regional Office Sea MST Marketing Sdn Bhd Uniplaster Industries Sdn Bhd UAC Berhad Hume Cemboard Industries Sdn Bhd Perceptive Profile Sdn Bhd ISO Marketing And Services Sdn Bhd IBS Interlocking Brick Sdn Bhd ID Interlocking Bricks Sdn Bhd Duralite (M) Sdn Bhd East Asia Modular Sdn Bhd

Head office
Selangor Selangor Selangor Selangor Selangor KL KL Selangor Selangor Perak Terengganu Terengganu Terengganu KL Sabah

No. of Factories
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

S'gor 1 1 1 1 1

KL

Kelantan

Sabah

TYPE 1A

1 1 1 1

1 1 1

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Innovative, panel and box systems are used in construction as ready made bathrooms, wall panels, dry walls and as well as staircases which are normally labour intensive items. All of the 15 manufacturers are single plant operators located mainly in Selangor, Perak, Terengganu Kelantan and one in Sabah.
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IBS Component manufacturing

Steel Formwork Systems Plants
# Name Head office Number of Factories
Column Beam

PRODUCTS
Slab Wall Staircase

FACTORY LOCATION
S'gor 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Johor

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PERI Formwork (M) Sdn Bhd Westform Industries Sdn Bhd MFE Formwork Technology Sdn Bhd HIFORM(M) Sdn Bhd Transkon Sdn Bhd Plastech Industrial Systems Sdn Bhd EFCO (M) Sdn Bhd Asiaric Contracts Sdn Bhd Fastsave Formwork Trading & Engineering Sdn Bhd Fuji Engineering Sdn Bhd LTH Engineering Sdn Bhd Floodlit Enterprise (M) Sdn Bhd BHS Plasticply (M) Sdn Bhd Simple Formwork Construction Sdn Bhd Mya Hitech Sdn Bhd TAC System Formwork Sdn Bhd

KL KL Selangor Selangor Selangor Selangor Selangor Selangor selangor Selangor Selangor Johor KL Selangor Johor Selangor

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1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

TYPE2

TOTAL

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There are currently 16 manufacturers registered under Type 2 Steel Formwork Systems. Every single one of them is a single plant manufacturer. They are only located in two states, Selangor (14) and Johor (2).

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IBS Component manufacturing

# Name Head office Number of Factories

Steel Framing System Plants

PRODUCTS
R oof T rus P ortal F rame S'gor 1 1 1 1 KL Johor

FACTORY LOCATION
Perak Pulau Pinang N. Sembilan Kelantan Sabah Sarawak

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29

Bluescope Lysaght (Malaysia) Sdn Bhd M- Truss Sdn Bhd Kamuja Fabricator Sdn Bhd KUTERA Resources (M) Sdn Bhd Great Allied Engineering Sdn Bhd SRT Building System Sdn Bhd Juta Steel Sdn Bhd UAC Stell System Sdn Bhd Pryda (M) Sdn Bhd Sunsrise Prima Sdn Bhd Dayatera Engineering Sdn Bhd Superspan Stell Sdn Bhd Lavenda Building Systems Tangsa Corporation Sdn Bhd Lotez Engineering Sdn Bhd Sarnho Preserver Sdn Bhd Sdn BhdF Builders Sdn Bhd Teguh Aluminium & Construction Sdn Bh Asia Roofing Industries Sdn Bhd Visage Industries Sdn Bhd Tong Yong Metal Sdn Bhd Brickwell Sdn Bhd Home Truss System Sdn Bhd Bluecsope Lysaght (Sarawak) Sdn Bhd Bluecsope Lysaght (Sabah) Sdn Bhd Manik Prestasi Sdn Bhd Rolfom Innovation Sdn Bhd Zamil Steel Building Wira Kerjaya Sdn Bhd

Selangor Selangor Selangor Selangor Johor Perak Selangor Selangor Selangor Selangor Selangor Selangor Selangor KL KL KL KL Johor Johor P.Pinang P.Pinang Kelantan Perak Sarawak Sabah Selangor KL Selangor

There are currently 29 registered manufacturers with a total of 27 plants in Malaysia; the remaining two manufacturers have their plants located overseas. All are single plant operators. 24 Zamil Steel Building operates 2 plants in Vietnam

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1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0

TY P E 3

1 1 1 1 1 1 1

1 1 1 1

1 1

1 1 1

1 1

1 VIETNAM CHINA

1 1

TOTAL

12

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IBS Component manufacturing

Prefabricated Timber Framing System Plants
# Name Head office Number of Factories PRODUCTS
R oof T rus 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Sunrise Prima Sdn Bhd Dayatera Engineering Sdn Bhd Mitek Asia Sdn Bhd Hong Giap Sdn Bhd Setia Wood Industries Sdn Bhd Woodlandor Roof Systems Sdn Bhd Kamuja Fabricator Sdn Bhd SBF Builders Sdn Bhd Tangsa Corperation Sdn Bhd Simpang Woodworking Sdn Bhd Pryda (M) Sdn Bhd Shing Huat Rooftruss Sdn Bhd Sarnho Preserver Sdn Bhd Pesama Timber Corporation Sdn Bhd KPMY Roof Builders Sdn Bhd Boh Huat Chan Timber Product Sdn Bhd Selangor Selangor Selangor Selangor Selangor Selangor Selangor KL KL Selangor Selangor KL KL Terengganu Terengganu Melaka 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 T imber F rame S'gor 1 1 1 1 1 1 1

FACTORY LOCATION
KL T'ganu Malacca

TYPE 4

1 1

1 1

1 1

1 1

16

TOTAL

All the 16 registered manufacturers are single plant operators. Plants are concentrated in Klang Valley (13), Terengannu (2) and Malacca (1). There are no plants in East Malaysia.

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IBS Component manufacturing

Blockwork Plants
# Name Head office Number of Factories
CMU SOLI D

PRODUCTS
CMU LIGH TWEIGH T CMU H OLLOW CMU IN TERLOCKIN G

FACTORY LOCATION
S'gor KL 1 1 1 1 1 1 1 1 1 1 Pulau Pinang Sabah Perak Pahang

1 2 3 4 5 6 7 8 9 10

Intergrated Brickwork Sdn Bhd Zenbes Sdn Bhd Multi Usage Holdings Berhad Brikform Sdn Bhd Exxomas (PG) Sdn Bhd Binaan Desjaya Sdn Bhd CSR Building Materials (M) Sdn Bhd Suprafoam Construction Technogies Sdn Bhd CKYJ (M) Sdn Bhd The Project Management Shop (M) Sdn Bhd

KL KL P.Pinang Sabah P.Pinang Pahang Selangor Sabah KL Selangor

1 1 1 1 1 1 1 1 1 1

TYPE 5

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TOTAL

There are 10 key players with 10 plants in total. The leading player with the most type of products is Integrated Brickwork The general view is that the manufacturers are not operating at optimal level.

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13

IBS Component manufacturing

# Name Head office
KL KL KL Selangor Selangor Selangor KL Selangor KL Selangor KL

On-Site IBS Manufacturers

PRODUCTS
PcBeam PcSlab PcWall/Panel PcStaircase

No.of Factories
PcColumm 1 1 1 1 1 1 1 1 1 1 1

1 2 3 4 5 6 7 8 9 10 11

Ibuzawa Corporation Sdn Bhd Global Prefab System Sdn Bhd Bumi Harus Sdn Bhd Pembinaan Era Dinamik Sdn Bhd Creative Precast Technics Sdn Bhd P&N Construction Sdn Bhd Niaga Sari Sdn Bhd Left -Right Construction Sdn Bhd Pembinaan Punca Cergas Sdn Bhd Pembinaan Ikhasas-Merak Sdn. Bhd Corporate Builders Sdn Bhd

TYPE 6

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TOTAL

On-Site IBS manufacturers are capable of producing columns, beams, slabs, wall panels and staircases. Almost all of the 11 players are producing precast staircases. Ibuzawa (who previously owns Precast Products), Global Prefab and Bumi Harus have the widest range of products.

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3,252 architects 59.304 engineers 2,081 quantity surveyors

Challenges and Lessons Learn Along the Construction Industry Value Chain
63,977 contractors 118 manufacturers

IBS Value Chain

Designers
Challenges Not a popular choice among designers because IBS perceived as limiting creativity in design Lack of IBS design knowledge among designers Proprietary systems make it hard to be adopted by designer

Contractors / Builders/ Owners

Current exemption from levy cannot cover additional cost for developers Insufficient push factor from the end buyer for IBS properties (except for GoM sector). Unlike Green Buildings where buyers knows the benefits and enjoy tax break for such buildings

IBS Manufacturing Base

Lack of volume and economies of scale due to non-standardisation of designs Lack of quality control in smaller IBS manufacturers Lack of local R&D, support services, technologies and testing labs Lack of innovative products that can enhance aesthetic values of buildings

Construction Site
Lack of on-site specialised skills for assembly and erection of components Lack of people with IBS project management skill which requires more logistics planning & coordination with IBS suppliers (i.e on-time delivery) Additional cost in hiring special equipment and machinery in implementing IBS (i.e heavy duty lifting crane)

The challenges faced have remain unchanged despite being repeatedly voiced by the industry stakeholders during surveys, forums and workshops through-out the yearsindicates problems need to be resolved at the root cause level

Standardisation Issue

Skills Issue

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IBS STANDARDISATION

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Komponen Struktur

1.Komponen Struktur

3.Komponen M&E

2.Komponen Kemasan

Bangunan Asas / Base Building

Komponen Kemasan

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Pelaksanaan Katalog IBS Kebangsaan

Penyeragaman Pelaksanaan Mencetuskan Industri IBS

ProjectOwner
Pelaksanaan Projek

KATALOG IBS KEBANGSAAN

Consultant
Garispanduan Rekabentuk Rujukan Piawaian IBS Rujukan MS1064

Contractor
Keperluan Kontrak Bangunan Mencapai IBSScore70%

Manufacturer
Garispanduan Pengilangan Komponen IBS Rujukan MS1064

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THE IBS CENTRE

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PUSAT IBS TINGKAT 1, BLOK E, LOT 8, JALAN CHAN SOW LIN, 55200 KUALA LUMPUR TEL: 03-9281 6909 FAX: 03-9281 5870

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Fasiliti Pusat IBS

Ch er as

Product Testing Facilities

Conventional Hall

Ja la

IBS Component Galleries

Entrance 2

Ja la n

Entrance 1 Existing IBS Gallery & Administration

Jalan C han

Sow Lin

Lo ke

IBS Village

Ye w

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5 Main Functions IBS Centre

5 Cores
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IBS Village

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GALERI IBS

Galeri IBS menawarkan informasi mengenai polisi dan insentif kerajaan, kategori IBS, produk IBS, R&D yang dijalankan dan lain-lain.

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Product & Service IBS : Verification & Certification

IBS Status Consultants IBS Status Contractor IBS Status Manufacturer IBS Status Installers

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Penyediaan Bahan, Dokumen, Sumber oleh Pusat IB

29 Penerbitan
Standard Malaysia (MS) Construction Industry Standards (CIS) National Occupational Skill Standards (NOSS) Siri Komponen IBS Piawai Siri Katalog Bahan IBS Manual Pengiraan Kandungan IBS Manual Penilaian IBS Perisian Semakan Kandungan Kordinasi Modular (MC Checker Software) Design Guide Transportation, Stacking and Installation Guide Buku-buku dan dokumen rujukan lain

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Conclusion

Quality controlled end products through controlled

prefabrication process and simplified installations

Faster completion of construction due to

usage of standardised prefabricated components and simplified installation process

Fewer site workers due to

simplified construction methods
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Source : Construction Industry Master Plan, 2006-2015

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Conclusion(continue..)
there is a need to re-align the industry framework to include private participation as potential for IBS in the private sector is nascent with huge opportunity but faced with challenges. These challenges must be overcome with private sector participation at the onset (i.e policy making stage). Standardisation needs to be developed and must be applied throughout the entire construction industry value chain. The manufacturing base needs to be expanded to support the construction industry

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THANK YOU

www.cidb.gov.my ibs@cidb.gov.my
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