1 RoadMap IBS

Industrialization of Construction Sector
Terms
MMC - Modern Method Construction OFFSITE Pre-casting /fabricating Out of Site IBS - Industrialised Building System
2
Industrialised Construction
Content
Introduction Current Scenario of Malaysian Construction Industry Promoting IBS Simplifying Construction The Way Forward Case Study Conclusion
Introduction
IBS Roadmap 2003-2010

Endorsed by the Cabinet 29th Oct 2003
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IBS ROADMAP 2003 - 2010

. the blueprint document towards achieving the Industrialization of the construction sector and the longer term objective of Open Building Concept.
Implementing the Roadmap

Policy
Cabinet
Ministry of Works
[Inter-Ministry coordination committee]
Implementation Ministries
Agencies
[Chaired by : KSU KKR]
CIDB
IBS Steering Com.
Coordinator/secretariat Stakeholders
Current Scenario of Malaysian Construction Industry
Poor Site Condition

Messy sites Poor S & H
High wastage
Labour intensive Low quality Delays
So what is construction now ?
DIRTY
DIFFICULT
DANGEROUS
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Promoting Industrialized Building Systems Simplifying Construction
Construction techniques in which components are manufactured in a factory, on or off site, positioned and assembled into a structure with minimal additional site works
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12
positioned and assembled into a structure with minimal additional site works
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Assembly of structural unit
Attachment of exterior walls Application of insulators
Assembly of ceiling frame Processing of steel

Assembly of floor frame
Assembly of sidewall frames
Attachment of interior walls
Manufactured House (Sekisui)
Incorporation of kitchen facilities
Incorporation of bath and sanitary facilities
Final inspection Installation Delivery Packing Shipment
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FIGURE 4.3 - Knowledge Industrialised IBS Survey 2005 in Survey on Building the Malaysian Architects Knowledge in Systems (IBS) IBS Construction
34%
66%
% GOOD % POOR
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IBS Survey 2005 in Survey the in FIGURE 4.5 - Experience Using IBSon Components Malaysian Architects Experience in Building Projects Using IBS Components
30%
70%
YES NO
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CHARACTERISTIC
1. Industrial production of components (prefab, pre-cast under controlled environment) or highly mechanised in-situ processes (slip forms, etc.) Labour reduction Modular Coordination - Open building concept Modern design / manufacturing (ex.CAD/CAM) Systematic Quality Control (ISO 9000 QMS)
2. 3. 4. 5.
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PRE-CAST CONCRETE FRAMING, BOX SYSTEMS
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PRE-CAST CONCRETE FRAMING
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STEEL FORMWORKS SYSTEMS
Tunnel forms, beams and column moulding forms, permanent steel formworks (metal decks), etc
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STEEL FRAME SYSTEMS
Steel beams and columns, portal frames, roof trusses, etc

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PREFAB TIMBER FRAME SYSTEMS
Timber frames, roof trusses, etc
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BLOCK WORK SYSTEMS
Interlocking concrete masonry unit, lightweight concrete blocks, etc

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BENEFITS
1. 2. 3. 4. 5. 6. Reduction of site labour Minimal wastage Less site materials Cleaner environment Controlled quality Neater and safer sites
7.
8.
Faster project completion

Lower construction costs
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Shorter construction period; if there is consistently large number of apartments to be constructed.

Time Scale (Months)
Precast System Production Foundation Erection Finishing Mechanical & Electrical Infrastructure Testing & commisioning Handing Over Overall completion Period Conventional System Foundation Construction- superstructure Finishing Mechanical & Electrical Infrastructure Testing & commisioning Handing Over Overall completion Period
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Concurrently done ( with 2 week lead time)
18 Month Completion
24 Month Completion
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Labour efficient through mechanisation, reduces 30% labour

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History
IBS Not A New Concept Concept of prefabrication started from the panellised timber houses shipped form England to the new settlements in America
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IBS in Malaysia
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IBS Components
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EARLY EFFORTS CIDBs efforts in promoting IBS started since 1998

Earlier, concentrated on Awareness/Promotion/ Training
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Usage
Usage of IBS in construction of buildings is still relatively very low if compared to infra works (bridges, tunnels, etc) Only 15% IBS in building Main Reason : Relatively cheap and abundant supply of foreign labour for Malaysian industry; labour cost in developed economies such as Finland 10 times the rates in Malaysia
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Labour is cheap, so why IBS?

Because labour is not going to stay cheap and abundant forever and disruption to supply is catastrophic
Industry needs better productivity, quality and safety to be globally competitive

Move towards k-economy
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IBS COMPONENTS ARE EXPENSIVE, SO WHY IBS?

True . components cost higher than conventional, but in-situ construction has hidden costs that usually leads to higher expenditure; due to rectifications, wastages, etc.
Cost higher because:

Low demand Low standardisation of components (moulds need to custom made or adjusted to suit orders)
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THE WAY FORWARD
IBS RoadMap 2003-2010
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Industrialised Construction Through Components Industry

RAILING COMPONENTS
STRUCTURAL COMPONENTS
BUILT-IN COMPONENTS
DOOR COMPONENTS
WINDOW COMPONENTS
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Standardisation/ Coordination
Dimensions
Technical compatibility
To facilitate open industrialization, coordination is needed in terms of :

Joints and details
Tolerance
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IBS - HOLLISTIC APPROACH
Designers, (architects, engineers)
IBS Component Catalogues Design Guides
Contractor, assemblers, fabricators

C l i e n t / A Vendors, s manufacturer s e t
m 39 a
Publication Materials
MS 1064 : 2001 :GUIDE TO MODULAR COORDINATION IN BUILDINGS

PART 1: PART 2: General Principles Storey and Room Heights
PART 3:
PART 4: PART 5: PART 6: PART 7: PART 8: PART 9:
Coordinating Sizes and Preferred Dimensions for Stairs and Stairs

Opening Coordinating Sizes and Preferred Dimensions for Doorsets Coordinating Sizes and Preferred Dimensions for Windowsets Coordinating Sizes and Preferred Dimensions for Rigid Flat Sheet Coordinating Sizes and Preferred Dimensions for Tiles Coordinating Sizes and Preferred Dimensions for Masonry Bricks and Blocks Coordinating Sizes and Preferred Dimensions for Cabinets
PART 10: Coordinating Sizes and Preferred Dimensions for RC Components
Gazetted Oct. 2002

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The Way Forward Modular Coordination (MC)
Modularisation
Based on MS1064, MC coordinates the positions, dimensions of components and spaces in building designs
Base module :
M = 100 mm
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Strategies
Promote industrialisation; Enforcement; Incentives; Awareness; Promotion; Training Main target housing sector Repetitive; High volume
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Current Scenario Closed System
Mula-mula: First a project Projek
Kemudian: Then a system Sistem
Always Bekalan: third Syarikat party supply tertentu
etc.
mass - production one end product
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Future Scenario
Open System
First a system
DESIGN GUIDE
Then many projects
Open supply
CATALOGUE
etc.
45
IBS Roadmap 2003-2010

FIVE main elements
1. Manpower 2. Materials/Components/Machines 3. Management/Process/Methods 4. Monetary/Economic/Financial 5. Marketing/Promotion
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MANPOWER
To have a labour policy that gradually reduces PERCENTAGE OF FOREIGN WORKERS from the current 75% to 55% in 2005, 25% in 2007 and 15% in 2009.
To incorporate IBS in CPD courses for architects, engineers and others. To incorporate SYLLABUS ON IBS in architecture, engineering, building courses in IPTs.
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MANPOWER
Continue efforts to develop NOSS (National Occupational Skill Standards). Continue Workers training and certification programme to include all types of IBS.
Commence training programme on mould making for IBS components. Commence industrial expertise awareness programme together with IBS manufacturer through on-job training.
48
MANPOWER
Commence site supervisory training and certification programme which includes knowledge on IBS To start BUMIPUTERA IBS MANUFACTURERS AND SPECIALISED CONTRACTORS training and financial aid
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MATERIALS
Enforce use of Modular Coordination based on MS 1064 through Uniformed Building By Laws (UBBL) by local authorities. Continue publishing reference books and case study reports regarding IBS. Continue writing new Malaysian Standards (MS) covering all types of IBS. Continue writing new Construction Industry Standards (CIS).
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MANAGEMENT
Develop software for MC components and dimensioning.
Include the IBS/MC knowledge into the standards of practice and training modules for the training and certification of Project Manager.
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MANAGEMENT
Offer specialised contractors training and certification programmes to cater for IBS related registration codes.
Continually update the website to disseminate information on IBS, MC and OBS.
52
MONETARY
Enforce IBS usage in government (building) projects in phases (from 30% in 2004 to 70% in 2008). Offer levy exemptions from 2004 for low cost, low medium cost and medium cost housing projects. Offer training schemes and financial loans for manufacture and contractors.
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MONETARY
Introduce Buildability Programme beginning 2006 for private (building) projects and enforcing it through the local Authorities in 2008.
Use IBS construct 30% of the 150,000 units of houses proposed to be built by Syarikat Perumahan Negara Berhad under the 2003 Economy Stimulus Packages.
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MARKETING
Publish IBS product catalogues.
Continue IBS/MC road show programmes at the national and international levels. Establish IBS as the main criteria for Malaysian Construction Industry Excellence Awards.
Introduce concept of Open building Systems to the industry. 55
2005 Budget
1. Directives
Govt building projects 50% IBS Score 100,000 affordable houses using IBS Zero levy for residential projects 50% IBS Score
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2. Incentive
-
IBS Scoring
Part 1 Structural Element (50%) Part 2 Wall Element (30%) Part 3 Other Simplified Solution (20%)
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Case Studies
SJK(C) DAMANSARA PETALING JAYA SELANGOR DARUL EHSAN

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Case Study
PROJECT DETAILS Cabinets directive - 31Januari 2001 To be completed in 2001 8 months project site : 2 .1 hectares possession of site : 1 February 2001 completion : 31 July 2001 construction period : 5 1/2 months
FEB 2001
Earth works
FEB - MAC 2001
Piling works
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Fast track project using prefabricated components Beams, floor slabs (half slabs with concrete topping) and staircases were prefabricated in the factory, wall panel are hollow blocks Columns and toilets were cast in-situ
Ground level
MAC 2001
Level 1
MAC 2001
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Level 2
MAC - APRIL 2001
Level 3
APRIL - MEI 2001
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Roof level
APR - MEI 2001
JUNE 2001
External works62
Front elevation
Back elevation 63
SEK. KEB. BRICKFIELDS 1, KUALA LUMPUR
IBS Structure: Hollowcore slabs; precast concrete columns & beams 9,900 m2, 4 Floors Completion in 8 months
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A compact design for two schools in land area of 48,200 m2.
Start of project Completion Period
: 6 February 2003 : 17 Sept. 2003 Industrialised Construction : 8 months
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installation of precast column

project constraints limited site, busy access, short construction period 75 % of building components were prefabricated
Prefab components used columns, beams, hollow core floor slabs, staircases, wall panels (Acotech panels)
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Installation of first floor slab on 02.05.03

Architectural features bright faade, cascading roofs with large overhangs, internal pockets of large and small courtyards
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Installation of 3rd floor slab on 28.05.03
fixing of wall panel
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Completion of external wall on 16.07.03

installation of precast staircases
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NEW DESIGN FOR GOVERNMENT QUARTERS

In 2001 new design alternatives for all categories of government quarters were initiated application of modular coordination use of building components flexibility and creativity in design and the concept of sustainable design standardised components for interchangeability between designs 70
Akademi Audit Negara, Nilai
Krtrs kelas F & G load bearing design, precast wall, slab, column & beam Industrialised Construction
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Balai Polis Senawang

Kuaters Kelas F Frame system : cast-in-situ column & beam, precast infill wall & slab
Kuaters Kelas G
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IBS PROJECTS
HOLLOWCORE SLABS; PRECAST CONCRETE COLUMNS & BEAMS 25,500 m2, 3 FLOORS STRUCTURAL CONSTRUCTION: 4 MONTHS
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DEWAN MILENIUM, KEPALA BATAS
PENANG STATE GOVERNMENT IBS STRUCTURE: HOLLOWCORE SLABS; PRECAST CONCRETE COLUMNS & BEAMS 7,500 m2, 4 FLOORS STRUCTURAL CONSTRUCTION: 2 Industrialised Construction MONTHS 74
INDOOR STADIUM, BALIK PULAU
MAJLIS PERBANDARAN PPINANG IBS STRUCTURE: HOLLOWCORE SLABS; PRECAST CONCRETE COLUMNS, BEAMS & BLEACHERS 6,000 m2, 3 FLOORS STRUCTURAL CONSTRUCTION: 2 MONTHS 75
RESIDENTIAL & OFFICE NORTHAM CITY, PULAU PINANG
IBS STRUCTURE: METAL FORMWORKS FOR WALLS, SLABS, BEAMS & COLUMNS
TWO 26-30 STOREY TOWERS (APARTMENTS & OFFICES) STRUCTURAL CONSTRUCTION: 6 MONTHS 76
IBS STRUCTURE: LIGHTWEIGHT BLOCKS & PRECAST CONCRETE WALLS; PRECAST CONCRETE SLABS 10,000 UNITS, 4-5 STOREY 109 LOCATIONS IN 9 STATES COMPLETION IN 3 YEARS
TEACHERS QUARTERS, ALL OVER MALAYSIA
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AKADEMI BINAAN MALAYSIA, SINTOK, KEDAH
CIDB MALAYSIA IBS STRUCTURE: PRECAST CONCRETE SLABS, BEAMS, COLUMNS & WALLS
9,600 m2, 6 WORKSHOP BLOCKS

STRUCTURAL CONSTRUCTION: 3 MONTHS 78
HOSPITAL SERDANG, SELANGOR
MINISTRY OF HEALTH 620-BED HOSPITAL HYBRID IBS STRUCTURE OF STEEL FRAMES; PRECAST CONCRETE SLABS; LIGHTWEIGHT CONCRETE BLOCKS FOR WALLS
130,000 m2, 9 FLOORS
STRUCTURAL CONSTRUCTION: 4 MONTHS 79 Industrialised Construction
SHOPPING COMPLEX, DAMANSARA
IBS STRUCTURE: SOLID & HOLLOWCORE SLABS; PRECAST CONCRETE WALLS, STAIRCASES, GUTTERS, BEAMS & COLUMNS
121,000 m2, 4 FLOORS, 2 BASEMENTS

STRUCTURAL CONSTRUCTION: 4 MONTHS
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RESIDENTIAL APARTMENTS, PUTRAJAYA
IBS STRUCTURE: PRECAST CONCRETE SLABS, WALLS & STAIRCASES 756 UNITS, 6 BLOCKS, 8-16 FLOORS CONSTRUCTION: 18 MONTHS 81
Conclusion
IBS ROADMAP 2003-2010: Towards labour reduction and better productivity, quality, safety & environment; reducing total industry costs INCREASING THE CONSTRUCTION INDUSTRY COMPETITIVENESS
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Thank You
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Industrialization of Construction Sector

IBS Roadmap 2003-2010

IBS ROADMAP 2003 - 2010

Implementing the Roadmap

[Inter-Ministry coordination committee]

[Chaired by : KSU KKR]

IBS Steering Com.

Current Scenario of Malaysian Construction Industry

Poor Site Condition

So what is construction now ?

Promoting Industrialized Building Systems Simplifying Construction

Assembly of structural unit

Attachment of exterior walls Application of insulators

Assembly of ceiling frame Processing of steel

Assembly of sidewall frames

Attachment of interior walls

Manufactured House (Sekisui)

Incorporation of kitchen facilities

Incorporation of bath and sanitary facilities

Final inspection Installation Delivery Packing Shipment

PRE-CAST CONCRETE FRAMING, BOX SYSTEMS

PRE-CAST CONCRETE FRAMING

STEEL FORMWORKS SYSTEMS

STEEL FRAME SYSTEMS

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

PREFAB TIMBER FRAME SYSTEMS

Timber frames, roof trusses, etc

BLOCK WORK SYSTEMS

Interlocking concrete masonry unit, lightweight concrete blocks, etc

Faster project completion

Shorter construction period; if there is consistently large number of apartments to be constructed.

Concurrently done ( with 2 week lead time)

Labour efficient through mechanisation, reduces 30% labour

EARLY EFFORTS CIDBs efforts in promoting IBS started since 1998

Labour is cheap, so why IBS?

Industry needs better productivity, quality and safety to be globally competitive

IBS COMPONENTS ARE EXPENSIVE, SO WHY IBS?

Cost higher because:

THE WAY FORWARD

IBS RoadMap 2003-2010

Industrialised Construction Through Components Industry

To facilitate open industrialization, coordination is needed in terms of :

IBS - HOLLISTIC APPROACH

Designers, (architects, engineers)

IBS Component Catalogues Design Guides

Contractor, assemblers, fabricators

MS 1064 : 2001 :GUIDE TO MODULAR COORDINATION IN BUILDINGS

Coordinating Sizes and Preferred Dimensions for Stairs and Stairs

PART 10: Coordinating Sizes and Preferred Dimensions for RC Components

Gazetted Oct. 2002

The Way Forward Modular Coordination (MC)

Current Scenario Closed System

Mula-mula: First a project Projek

Kemudian: Then a system Sistem

Always Bekalan: third Syarikat party supply tertentu

mass - production one end product

Then many projects

IBS Roadmap 2003-2010

SJK(C) DAMANSARA PETALING JAYA SELANGOR DARUL EHSAN

FEB - MAC 2001

MAC - APRIL 2001

APRIL - MEI 2001

APR - MEI 2001