CHAPTER 2

INDUSTRIALIZED BUILDING SYSTEM (IBS) IN MALAYSIA

CHAPTER 2

INDUSTRIALIZED BUILDING SYSTEM (IBS)

2.0 DEFINITION OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

Before defining what Industrialized Building System (IBS) means, it is better to understand the meaning of the Industrialization. According to Wikipedia (2007), Industrialization means a process of converting to a socioeconomic order in which industry is dominant. In relation to the construction industry, the term refers to a method of technological advancement applied in construction process which employed from manufacturing industry (Warszawski, 1999). Warszawski (1999) further says that subsequent automation and prefabrication are the concept of industrialization in manufacturing process and has been inhibited to the construction industry since the 18th century. In the late 1900s, the process of industrializing the construction industry has introduced a new form of construction system so called Industrialized Building System (IBS) which not only regards to the construction and production itself but also the aspect of informative technology, economical , coordination and management ( Roy, Low & Waller, 2005).

The general definition of IBS covers all types of structure, as the word building actually relates to constructing. According to Warszawski (1999), IBS can be defined as: Construction systems in which components are manufactured in a factory, on or off site, positioned and assembled into a structure with minimal additional site works

In addition, Gibb (1999) described IBS literally as assemble before. IBS or prefabrication/pre-assembly covers the manufacture and assembly (usually off-site) of buildings or parts of buildings or structures earlier than they would traditionally be constructed on site, and their subsequent installation into their final position (Gibb,

1999).For the purpose of this research, the definition asserted by Thanon, Samad, Kadir and Ali (2003) will used as it is comprehensive and conclusive. According to Thanon et al (2003), IBS be defined as an industrialized process by which components of a building are conceived, planned, fabricated, transported and erected on site. Thanon et al (2003) added that the systems include system design, which is a complex process of studying the requirement of the end user, market analysis, development of standardized components, establishment of manufacturing and assembly layout and process, allocation of resources and materials, conceptual framework and management.

2.1

HISTORY OF INDUSTRILIZED BUILDING SYSTEM (IBS)

2.1.1

International

According to Warszawski (1999), the idea of industrializing building components is not new and can be traced back to early 1624 when panelized timber houses were shipped from England to the new settlement in North America. The Industrial Revolution of the 1700s provided the construction industry with technological boost (Warszawski, 1999). He claimed that the construction of the first cast iron bridge across the Severn Gorge, at a place now known as Iron Bridge in Shropshire, England revolutionized the way structures were built.

After that, various outstanding iron-based structures were constructed: including the modular-dimensioned Crystal Place in Hyde Park, London for the 1851 Great Exhibition and the Eiffel Tower for the Paris World Expo and French Revolution centenary Celebration in 1889 (Warszawski, 1999). According to Tatum (2000), the development of steel and other pre-engineered materials promoted the race to build tall structures, particularly in the United States where steel frames are often combined with pre-cast panels in building skyscrapers.

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2.1.2

Malaysia

According to Thanon et al (2003), the idea of using industrialized building system in Malaysia was first mooted during the early sixties when the Minister of housing and Local Government visited several European countries and evaluated their building systems performance. Thanon et al (2003) added that, through the visit, the government took a brave decision to try two pilot projects which were the Pekeliling Flats in Kuala Lumpur and the Rifle Range Road Flats in Penang using IBS concepts. According to Thanoon et al (2003), the first pilot project was constructed on 22.7 acres of land along Jalan Pekeliling which included the construction of 7 blocks of 17-storey flats and 4 blocks of 4-storey flats comprising about 3000 units of low cost flats and 40-storey shop lots. The project was awarded to the Gammon/Larsen Nielsen using the Danish System of large panel industrialized prefabricated systems.

Meanwhile, the second pilot project was built in Penang with the construction of 6 blocks of 17-storey flats and 3-blocks of 18-storey flats comprising 3,699 units and 66 shop lots along Jalan Rifle range. The project was awarded to Hochtief / Chee Seng using the French Estiot System (Thanon et al, 2003). Following these pilot projects, Perbadanan Kemajuan Negeri Selangor (PKNS) between the years 1981 and 1993 had acquired pre-cast concrete technology from Praton Haus International, Germany and involved in numerous housing projects ranging from low cost houses to high cost bungalows (Eddie, 2005).

According to Sharul (2003), the uses of IBS have increased, particularly during the years 1995-1998 which include the construction of the Bukit Jalil Sports Complex and Games Village, the Petronas Twin Towers and the LRT lines and tunnels. He added that other projects include the construction of elevated highways using pre-cast concrete box girder as well as the monorail lines utilizing arched pre-cast concrete beams. However, it appears that the usage of IBS in Malaysia is still low compared to that of other developed countries such as Japan, UK, Australia and the United States of America (Sharul, 2003).

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2.2

TYPES OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

Based on the structural aspects of the systems, IBS can be divided into five common types which are currently available in Malaysia (CIDB, 2005). i. ii. iii. iv. v. Precast Concrete Components System Steel Framing Systems Steel/Alumnium Formwork Systems. Prefabricated Timber Framing Systems Blockworks Systems

2.2.1

Precast Concrete Components System

Precast Concrete Component System is one of the IBS construction systems which are mainly used for local building infrastructure projects (IBS Survey, 2003). Precast components come in a variety of shapes for different types of usage, both architectural and structural. It includes the traditional precast beams, columns, slabs, walls, staircases, parapets and drains; as well as other relatively new precast components for toilets, pile caps, facades, lift shafts and refuse chambers.Precast concrete components produced either in factory based production (close and open site casting ) cast ( open site). or on site

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Figure 2.0- Types of precast concrete component available in local market Source: CIDB (2005). Precast Concrete Construction IBS Digest -1 ,p.11-14

In building projects, CIDB (2005) indicates that precast concrete components can be categorized into (3) three main types which are: 1. Framing system 2. Wall system 3. 3-D Components 2.2.1.1 Framing System Column, beam, slab etc

This IBS system is suitable for buildings that need a high degree of flexibility in terms of larger clear distances between columns. As a result, the longer spans give bigger open span and greater freedom for designing the floor areas. The system can be used for buildings that offer a certain luxury of space such as in the case of office buildings, school buildings, hospitals, university buildings, commercial buildings and car parks. Therefore, the system normally chosen for any type of building is because of its common requirement, such as: Requirement with respect to comfort such as a spacious area Flexibility for future modification Ample floor-to-floor clearance height

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Figure 2.1- Precast Concrete Beam

Figure 2.2- Precast Concrete Column

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Figure 2.3 Precast Concrete Hollow Slab Source: Catalogue, Eastern Pretech Sdn Bhd (2008)

2.2.1.2

Wall System

Precast concrete wall building is a system in which the structural framework of the building is composed of precast concrete slabs and load bearing walls. This system is preferred for the construction of simple and uncomplicated buildings such as hotels, hostels and government apartments such as teachers quarter. These buildings normally offer a lesser degree of flexibility in which major modifications, such as the removal of load-bearing walls, are restricted during their service life. CIDB (2005) stated that there are (3) three classes of precast concrete walls namely: 1. Load bearing wall Load bearing walls are structural elements that carry vertical load from slabs to the foundation.

2. Shear wall Walls taking lateral loads from wind or earthquake are normally referred to as shear wall.

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3. Partition wall Partition walls are used to divide the area of a room into several functions and categorized as non-structural elements, and may be removed if required.

Figure 2.4- Precast Concrete Internal Wall

Figure 2.5 Precast Conc. External Wall

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Figure 2.6- Erection process of wall panel Source: IBS Road Show 2005, Architect branch of PWD

2.2.1.3.1

3-D Components

The examples for this type of precast component systems are balconies, staircases, toilets, lift chambers, refuse chambers etc.

Figure 2.7- Precast Concrete Staircase Source: Catalogue, Eastern Pretech Sdn Bhd (2008)

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2.2.2

Steel Framing System

Steel Framing System is one of the IBS components available in Malaysia. According to Watson (2003), steel framing has become a very innovative industry with technical developments leading to high quality housing construction at a very competitive price. Steel has been used for more than 150 years in shaping the built environment. Although the idea of steel conjures up images of a heavy or cumbersome material, the steel used in residential construction is quite the opposite. Cold-formed steel is lightweight, easy to handle, cost effective, and a high quality alternative to traditional residential framing materials. Steel offers the builder a strong, dimensionally stable, easy-to-work framing system. There are three basic residential steel framing methods: stick-built, panelized, and pre-engineered.

1.

Stick-built

Replace wood members with steel members (one-for-one). As shown below in Figure 2.8, the steel-framed non-load-bearing wall appears very similar to that of a comparable wood-frame.

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Figure 2.8 Steel stilt-up framing method Source: http://www.toolbase.org/Construction-Methods/Steel-Framing/designing-homes-cold-formedsteel

2.

Panelized

Factory-assembled panels delivered to site and assembled. The panelized approach represents an efficient approach for repetitive building designs and, as a result, is a popular approach in hotel/motel construction and other multi-unit applications i.e. floor frame.

3.

Engineered

Location and placement of framing members is engineered to take advantage of steels properties. Spacing of framing members may increase to as much as 8-feet (2-3 meters) with horizontal stabilizers.

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According to Watson (2003), the most widely adopted method is that of factory prefabrication of floor frame units, wall frame units, and roof trusses of transportable size, which are then assembled and erected in place on site. Meanwhile, the less popular approach is to deliver the pre-cut straight members to site and carry out all fabrication and assembly on site for instance structural steel frame (NASH, 2003).

Figure 2.9- Steel-framed wall

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Figure 2.10- Steel floor frame

Figure 2.11- Steel roof trusses

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Figure 2.12- Steel structural frame

Figure 2.13- Steel structural frame (column and beam) Source: http://www.toolbase.org/Construction-Methods/Steel-Framing/designing-homes-cold-formedsteel

Commonly used with pre-cast concrete slabs, steels columns and beams, steel framing systems have always been the popular choice and used extensively in the fast-track construction of skyscrapers. Recent development in this type of IBS includes the increased usage of light steel trusses consisting of cost-effective profiled cold-formed channels and steel portal frame systems as alternatives to the heavier traditional hotrolled sections.

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2.2.3

Steel / Aluminum Formwork System

According to Sharul (2003), Steel/aluminium formwork system is considered as one of the low-level or the least prefabricated IBS, as they generally involve site casting. It can be reused more than 500 times which results in higher productivity, efficiency, economy and quality. The usage of Formwork systems has now become a trend in the Malaysian construction industry, especially for high rise buildings (CIDB, 2005).

Recognized as one of the Industrialised Building Systems (IBS), Formwork system simplifies the whole construction process by enabling a smooth and fast operation that can result in cost effectiveness, productivity and high quality finished. Formwork systems have proven that impressive results can be achieved in terms of productivity, efficiency, economy and quality (CIDB, 2005). It can usually be reused for 500 to 1,000 times, and is an effective way to construct buildings that have repetitive elements or layouts. The system is now one of the most preferred methods of cellular construction by the contractors in Malaysia whilst clients appreciate formwork system ability to deliver projects to budget and on time. The types of formwork system are include tunnel forms, tilt-up systems, beams and columns moulding forms, and permanent steel formworks (metal decks).

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Figure 2.14- Aluminium mould for column

Figure 2.15- Column and beam formwork

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Figure 2.16- Tunnel formwork

Figure 2.17- Tilt-up formwork system Source: PECB (2007), Presentation on PECB experience in IBS construction system

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2.2.4

Prefabricated Timber Framing System

The most dominants components in fabricated timber are timber building frames and timber roof trusses (Rozaimah, 2004). According to Sharul (2003), it is estimated that across all the developed countries, timber frame accounts for around 70% of all housing stock, representing some 150 million homes. He also stated that, in terms of sustainability, timber is possibly the only renewable resource in the construction sector and contains less embodied energy than comparable building materials. Palmer (2000), Rozaimah (2004) and Eddie (2005) also noted that, there are 3 main methods of timber framing system namely, which are:

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

2. Hand erect (Small panel) Components are assembled off-site in timber frame factories.

3. Crane erects (large panel or whole-room). Similar to small panel only the panels can be up to 9.6 meters long and require a crane to erect them as they are too heavy to maneuvers by hand. Crane erect also enables the use of whole-room construction or volumetric techniques.

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Figure 2.18- Timber frame for wall

Figure 2.19- Prefabricated timber roof truss system

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Figure 2.20- Joint of prefabricated timber roof truss system Source: CIDB (2004) Timber framing as Industrialised Building System (IBS)

Among the products listed in the figures shown above is the timber building frames and timber roof trusses. While the latter is more popular, timber building frame systems also have their own good market; offering interesting designs from simple dwelling units to buildings that require high aesthetical values such as chalets for resorts. According to Eddie (2005), the timber framing system that is usually used in Malaysia is the prefabricated timber roof truss system, specifically in public projects.

2.2.5

Blockwork system

Block work system usually refer to the interlocking concrete masonry units (CMU) and lightweight concrete blocks is applied to replace the construction method of using conventional bricks where it save in term of time compare to time-consuming traditional brick-laying tasks (Sharul, 2003). CMU or the aforesaid blocks are available in various grades and sizes to cater for most building design requirements. Maximum productivity is achieved by the use of large format blocks system, which are sufficiently lightweight for easy handling.

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Block work system can be used in a number of applications including the inner leaf of cavity walls, party walls and partitions. It is also well suited to external solid walls where the productivity gains are equally applicable. CMU or lightweight concrete blocks system walls can be finished externally in a variety of ways including insulated render and brickwork as well as traditional cladding materials.

Figure 2.21- Lightweight blocks

Figure 2.22- Blockworks system approach

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Figure 2.23- A house being constructed through blockworks system Source:Matthew(2006),Durox blockworks system;London,TarmacTopblock

The construction method of using conventional bricks has been revolutionized by the development and usage of interlocking concrete masonry units (CMU) and lightweight concrete blocks. The tedious and time-consuming traditional brick-laying tasks are greatly simplified by the usage of these effective alternative solutions.
PRECAST CONCRETE FRAMING SYSTEM STEEL FRAMING SYSTEM

INDUSTRIALIZED BUILDING SYSTEM (IBS) IN MALAYSIA

STEEL FORMWORK SYSTEM

BLOCKWORK SYSTEM PREFABRICAED TIMBER FRAMING SYSTEM

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

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2.3

CHARACTERISTIC OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to Thanon et al (2003), there are essential characteristics underlining the successful implementation of industrialized building system (IBS) in general. Each of them is briefly discussed below.

2.3.1

Closed System

A closed system can be classified into categories, namely production on the clients design and production based on the precasters design. The first category is designed to meet a spatial requirement of the client that is the spaces required for various functions in the building as well as the specific architectural design. In this instance, the clients needs are paramount and the precaster is always forced to produce a specific component for a building. On the other hand, the production based on the precasters design includes designing and producing a uniform type of building or a group of building variants, which can be produced with common assortments of components. Such buildings include school parking garage, gas station and low cost housing. Nevertheless these types of building arrangements can be justified economically only when the following circumstances are observed (Warszawski, 1999):-

a) The size of project is large enough to allow for distribution of design and production costs over the extra cost per component that incur due to the specific design.

b) The architectural design observes large repetitive elements and standardization. In respect to this, a novel prefabrication system can overcome the requirement of many standardized elements by automating the design and production process.

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c) There is a sufficient demand for a typical type of building, such as schools, so that a mass production can be obtained.

c) There is an intensive marketing strategy by precaster to enlighten the clients and designer about the potential benefit of the system in term of economics and non- economic aspects.

2.3.2

Open System

In view of the limitations inherent in the closed system, an open system which allows greater flexibility of design and maximum coordination between the designer and precaster has been proposed. This system is plausible because it allows the precaster to produce a limited number of elements with a predetermined range of product and at the same time maintaining architectural aesthetic value.

Despite the many advantages inherent in an open system, its adoption experience one major setback. For example, joint and connection problem occur when two elements from different system are fixed together. This is because similar connection technology must be observed in order to achieve greater structural performance.

2.3.3

Modular Coordination

Modular co-ordination is a co-coordinated unified system of dimensioning spaces, components, fitting, etc. so that all elements fit together without cutting or extending, even when the components and fittings are manufactured by different suppliers (Trikha, 1999). The objectives of modular coordination are:

a) To create a basis upon which the variety of types and sizes of building components can be minimized. Through a rationalized method of construction, each component is designed to be interchangeable with other similar ones and

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hence, provide a maximum degree of freedom and choice offered to the designer. This can also be accomplished by adopting a relatively large basic measurement unit (basic module0 and by limiting the dimension of building components to a recommended preferred sizes (Warszawski, 1999).

b) To allow for easy adoption of prefabricated components to any layout and for their interchangeability within the building. This is achieved by defining the location of each component in the building with reference to a common modular grid rather than with a reference to other components (Warszawski, 1999)

The modular coordination for building components apply the basic length unit or module of M=100cm. This allows the designer to apply this size or its multiple in the production of building components. Although this concept seems to be easy to adopt, its application involves a great degree of coordination and adjustment in the manufacturing process and the interfacing aspects of component.

2.3.4

Standardization and Tolerances

In order to accomplish the requirement of modular co-ordination, all components need to be standardized for production. Such standardization of space and elements need prescribing tolerances at different construction stages such as manufactured tolerances, setting out tolerances and erection tolerances, so that the combined tolerance obtained on statistical consideration is within the permitted limits (Trikha, 1999).

Production resources can be used in the most efficient manner if the output is standardized. Then the production process, machinery, and workers training can be best absorbed to the particular characteristic of the product.

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2.3.5

Mass Production

The investment in equipment, human resources, and facilities associated with industrialization can be justified economically only when large production volume is observed. Such volume provides a distribution of the fixed investment charge over a large number of product units without unduly inflating their ultimate cost.

2.3.6

Specialization

Large production output and standardization of precast elements allow a high degree of labour specialization with the production process. The process can be subdivided into a large number of small homogeneous tasks. In such working conditions, workers are exposed to their work repetitiously with higher productivity level (Warszawski, 1999).

2.3.7

Good Organization

High production volume, specialization of work, and centralization of production requires an efficient and experienced organization capable of a high level of planning, organizing, coordination and control function with respect to production and distribution of the products (Warszawski, 1999).

2.3.8

Integration

In order to obtain an optimal result, a high degree of coordination must exist between various relevant parties such as designer, manufacturer, owner and contractor. This is achieved through an integrated system in which all these functions are performed under a unified authority (Warszawski, 1999).

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2.3.9

Production Facility

The initial capital investment for setting up a permanent factor is relatively expensive. Plant, equipment, skilled worker, management resources need to be acquired before production can be commenced. Such huge investment can only be breakeven if there is sufficiently high demand for the products. On the other hand, a temporary casting yard or factory can be established at the project site in order to minimize the transportation cost.

2.3.10 Transportation

It is found that casting of large panel system can reduce labour cost up to 30 percent. However, these cost savings are partially offset by the transportation cost. The transportation of large panel system is also subject to the countrys road department requirement. This limitation must be taken into consideration when adopting a prefabrication system.

2.3.11 Equipment at Site

For the purpose of erecting and assembling precast panels into their position, heavy crane is required, especially for multi-storey building. It is therefore important to incorporate this additional cost when adopting a prefabrication system (Warszawski, 1999).

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ESSENTIAL CHARACTERISTIC OF SUCCESSFUL IMPLEMENTATION OF IBS

MODULAR COORDINATION GOOD ORGANIZATION MASS PRODUCTION TRANSPORTATION

EQUIPMENT AT SITE CLOSED SYSTEM SPECIALIZATION OPEN SYSTEM PRODUCTION FACILITY INTEGRATION

STANDARDIZATION & TOLERANCE

Figure 2.25 Essential Characteristic of IBS

2.4

BENEFITS OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to CIDB (2003), Industrialized Building System (IBS) has the following benefits when compared to the conventional construction method.

i. ii.

Low site workers requirement due to simplified construction methods. Quality-controlled and highly aesthetic end products through the process of controlled pre-fabrication and simplified installations.

iii.

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

iv.

Reduction of elimination of conventional timber formworks: replaced by prefabricated components and alternative moulds with multiple-usage capability.

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v.

Reduction or elimination of props due to the absence of conventional timber props and usage of prefabricated components.

vi.

Reduction of construction waste with the usage of the standardized components and less in-site works.

vii. viii.

Cleaner sites due to lesser construction waste. Safer construction sits due to the reduction of site workers, materials and construction waste.

ix.

Faster completion of construction projects due to the usage of standardized prefabricated components and simplified installation processes.

x.

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

2.5

SHORTCOMINGS OF INDUSTRIALIZED BUILDING SYSTEM (IBS)

According to Thanon et al (2003), the adoption of IBS is not without its limitations and shortcomings, these shortcomings of an IBS system are as discussed below:

i.

An IBS system can only be acceptable to practitioners if its major advantages are valuable compared to the conventional system. However, as to date, there is inadequate corroborative scientific research undertaken to substantiate the benefits of IBS system. It is therefore, arguable that the implementation of IBS is particularly hindered by lack of scientific information in relation to the Malaysian construction industry,

ii.

Standardization of building elements faces resistance from the construction industry due to aesthetic reservation and economic reason. One good example of this is when a 300mm thick modular standardized floor slab has to be used although a 260mm thick floor slab can achieve the similar structural performance. This results in wastage of material.

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iii.

The selection of a new IBS has been hindered by lack of assessment criteria set by the approving authorities. This phenomenon has been even more detrimental to the development of an indigenous IBS. With such reason, absence of the assessment criteria has been identified as the most important inhibitor to the introduction of IBS in construction industry.

iv.

A general decline in demand and volatility of the building market for large public housing projects in most developed countries make an investment in IBS more risky compared with the conventional labour intensive methods. This reason is substantiated by a cheap imported labour in several European countries (Warszawski, 1999).

v.

The industrialization of building process which emphasizes on the repetitiveness and standardization cause monotonous barrack like complexes that very often turns into dilapidated slums within several years. This shortcoming is further reinforced by production defects in building components which are quite frequent in the initial stages of prefabrication. Such defects resulting from lack of technical expertise and poor quality control cause aesthetic and functional faults, such as cracks, blemishes, moisture penetration, and poor thermal insulation in completed building (Warszawski,1999).

vi.

Prefabricated elements are considered inflexible with respect to changes which may be required over its life span. This may occur when small span room size prefabrication is used (Warszawski, 1999).

vii.

At university level, students are less exposed to technology, organization and design of industrialized building system. The academic curriculum seldom includes courses that incorporate a thorough and methodological manner, the potential and the limitations associated with industrialization in building. As consequences, there is a natural tendency among practitioners to choose

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conventional methods perhaps with occasional utilization of single prefabricated elements (Warszawski, 1999).

viii.

The weakness of existing industrialized building system is still in its cumbersome connections and jointing methods which are very sensitive to errors and sloppy work. Also, standardization of joint and connection detail may delay the evolution of new technology.

ix.

An adaptation of standardization requires a tremendous education and training effort. Hence, it requires an initial immense of investment cost. This is cited as one of the greater hindrances to the use of modular coordination in IBS.

2.6

GROWTH OF THE USAGE OF IBS IN MALAYSIA CONSTRUCTION INDUSTRY

According to CIDB (2005), since the resolution made during the Colloquium on Industrialized Construction system in 1998, CIDB Malaysia as the lead secretariat for the construction development in Malaysia has been concentrating in doing promotions and training on IBS and it has since shown some positive results. It was concluded in a report that productivity growth in the industry was attributed by greater efforts made in promoting IBS in order to increase productivity and quality of output (NPC, 2004). As highlighted in Table 2.1, percentage of projects using at least a form of IBS had increased steadily from 1998 (Sharul, 2003).
1998 Productivity growth for construction (%) -12.71 1999 -4.91 2000 2.33 2001 0.39 2002 2.51 2003 2.55

Percentage of completed projects 21 24 30 34 42 using at least one form of IBS (%) Table 2.1-Comparison between Productivity Growth and Usage of IBS in Malaysian Construction Industry

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While the efforts seem to be successful, there is still a lot of room for improvement (Sharul, 2003). He added that a greater coordination of the whole industry is needed for a greater success in the promoting IBS. In coordinating the industry towards greater usage of IBS in construction, CIDB in 2003 has formulated it master plan with the guidance from the IBS steering committee that are represented by the stakeholders of the industry (Sharul, 2006). According to him, the master plan fully known as Industrialized Building System (IBS) Roadmap 2003-2010, is based on the Five (5) MStrategy namely (Manpower, Material-Components-Machines, Management-ProcessesMethods, Monetary and Marketing) with the target of having an industrialized construction industry by the year 2010 .

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

i.

To have a labour policy that gradually reduces percentage of foreign workers from the current 75% to 25% in 2007 and 15% in 2010.

ii.

To enforce minimum IBS content for private developers from 2008.

iii.

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

iv.

To enforce Modular coordination through amendments to the Uniform Building By-Laws (UBBL) from 2004.

v.

To develop a series of catalogue for the building components (Precast concrete standard components by 2004).

vi.

To develop an IBS Verification Scheme as a quality assurance programme for IBS components by 2005.

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vii.

To enforce utilization of IBS in government building projects-from 30% gradually increased to 50% in 2006 and 70% in 2008; commencing from inception stage of public project.

viii.

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

ix.

To start Bumiputera manufacturers and specialized contractors (installer) training and financial aid programmes by 2004, and

x.

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

In order to provide the kick-start element of the master plan, initial boost from the government was needed (CIDB, 2005). According to CIDB (2005), through the 2005 Budget Speech; the government has addressed a number of initiatives to cater for the demand side of the implementation of IBS and strengthen the industrialization agenda in construction as illustrated in Figure 2.3.
First Announcement The government has pledged to construct 100,000 units of affordable houses using IBS

Second Announcement The government requires that all government buildings to be constructed using a minimum of 50% IBS content.

Third Announcement All contractors who built housing projects using more than 50% IBS content would be given incentives in the form of full exemption of CIDB levy.

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

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According to Sharul (2006), the directive of 50% IBS content for government building project was in fact made one year ahead of the IBS Roadmap target; showing full commitment by the government in supporting the industrialization agenda. In the 2006 Speech Budget, the government has pledged to continue supporting IBS usage as well as ensuring all IBS components to meet the Modular Coordination (MC) standard MS 1064 which a guide line to coordinating dimension and space of which buildings and components are dimensionalised and positioned in basic units or modules (CIDB, 2005).

According to CIDB (2005), the implementation of IBS would increase once the new projects under the Ninth Malaysian Plan (9MP) being awarded starting from 2006. Besides, Sharul (2006) mentioned that the IBS components would contribute to greater demand in the future whereby the need of renewable energy in building components to be supplied as the wake of the escalating oil prices. According to him, a greater demand of IBS components in public projects is expected to be experienced by the increasing IBS manufacturers in Malaysia. As stated in Table 2.2, there are currently 129 manufacturers of various IBS product in Malaysia (CIDB, 2005).
IBS Product type Precast concrete Frames/ Panels / Box & Precast Block Steel Frames System Formworks (steel ,etc) Prefabricted Timber Frames TOTAL Manufacturer 50 27 24 28 129 Table 2.2 Number of IBS Manufacturers as of 17th October 2005

The demand of IBS in the future will contribute to the success of the industrialization agenda of the government in construction sector; however the agenda should incorporate the industry players; Builder, Developers, Architects, Engineers and especially the Quantity Surveyor (Sharul, 2006).

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2.7

SUMMARY

Based on this chapter, the overview of the concept of industrializing construction activities generally has been discussed. The discussion also included the revolution of industrialization in the construction sector globally and specifically in Malaysia. In addition to that, thorough study on the implementation of IBS in Malaysia has also been conducted in term of the available types of IBS, its characteristic and growth of IBS. Finally, the benefits and shortcoming of IBS also been elaborated.

The latter chapter will discuss on the project management during construction stage generally and specifically to construction management aspects. Furthermore, factors and components will be identified that may contribute to construction cost during construction phase.

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