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Assoc Prof Dr Assoc Prof Dr TaksiahTaksiah A.MajidA.Majid

School of Civil EngineeringSchool of Civil Engineering

Universiti Sains MalaysiaUniversiti Sains Malaysia

INTRODUCTION OF IBS IN CONSTRUCTION INDUSTRY

PoliteknikPoliteknik UngkuUngku Omar, 25 Nov 2010Omar, 25 Nov 2010

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TOPIC 1TOPIC 1 : IMPLEMENTATION OF IBS IN : IMPLEMENTATION OF IBS IN

MALAYSIA & CHALLENGE IN THE IBS MALAYSIA & CHALLENGE IN THE IBS

INDUSTRYINDUSTRY

TOPIC 2TOPIC 2 : INTRODUCTION TO MODULAR : INTRODUCTION TO MODULAR

COORDINATIONCOORDINATION

TOPIC 3TOPIC 3 : BUILDIBILITY OF DESIGN: BUILDIBILITY OF DESIGN

CONTENT OF PRESENTATION

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IMPLEMENTATION OF IBS IN MALAYSIA & IMPLEMENTATION OF IBS IN MALAYSIA &

CHALLENGE IN THE IBS INDUSTRYCHALLENGE IN THE IBS INDUSTRY

TOPIC 1 :

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Presentation Outline For Topic 1

• 1. IBS in Malaysia

• 2. Government Policies on IBS

• 3. Current Status & Challenges

•4. The IBS Centre

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IBS IN MALAYSIAIBS IN MALAYSIA

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WHAT IS IBS?

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“A construction technique in which components are manufactured in a

controlled environment (on or off site), transported, positioned and assembledinto a structure with minimal additional

site works”

Definition of Industrialized Building Systems (IBS)

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)

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TYPE 2: STEEL FORMWORK SYSTEMS

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

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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 IBSGOVERNMENT POLICIES IN IBS

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IBS Roadmap 2003-2010 & 3 Main Objectives

Approved by the Federal Cabinet Ministers Approved by the Federal Cabinet Ministers on 29 October 2003on 29 October 2003

• 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.

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• To all Federal Ministries, Head of Departments, State Governments, Regulatory bodies, and Local Authorities.

Treasury Circular on IBS - 31 Oktober 2008

• Adoption of Open System methodology through the use of Modular Coordination, MS 1064.

• Requirement of 70% IBS content in Governmentprojects.

• National IBS Sectretariat as the Coordinator through the Ministry of Works.

• Implementation Coordination Unit of PrimeMinister’s Department as the monitoring unit.

• IBS Centre as the One Stop Centre.

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FEDERAL MINISTERS

CABINET COMMITTEE ON INVESTMENT AND INFRASTRUCTURE

IBS MAIN COMMITTEEChairman : Chief Secretary Members: Centralised Agencies & MinistriesSecretariat : Implementation Coord. UnitScope : Coordination on IBS Policies

NATIONAL IBS SECRETARIATChairman : Ministry of WorksMembers : Centralised Agencies & MinistriesSecretariat: Ministry of WorksScope : IBS Projects Implementation

IBS COMPONENTS MGMT COMMITTEEChairman : CIDB MalaysiaMembers: Representatives of Construction IndustrySecretariat: CIDB MalaysiaScope : Coordination at industry level

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

IBS ENFORCEMENT MONITORING COMMITTEE

Chairman: Implementation Coord. Unit Members : Public Works Dept., ICU & TreasurySekretariat : TreasurySkop : Monitoring the Enforcement of Government Circular on IBS

Monitoring Structure on Government IBS Projects Implementation

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Key Milestones from 1999 to 2010

2004 2005 2006 2007 2008 2009 20152003

MS 1064: Modular Coordination as Guideline for Building DesignJoint 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

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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

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

Singapore

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

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

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

Purpose

Integration of design - build

Responsibility of architects

Coverage

Approval to build

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.

Clear path

Best Practices

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IBS Component manufacturing# Name Head office

Number of Factories

P recas t 

C olumnP recas t B eam Prec as t S lab

P c  Wall/ 

Panel

Precas t 

S tairc as eS'gor Johor Perak N. S. Malacca Pahang T'ganu Kedah P.

Pinang Sabah Sarawak

1 MTD ACPI Engineering Berhad Selangor 6 1 1 1 1 1 12 Hume Concrete Marketing Sdn Bhd Selangor 5 1 1 1 1 13 HL- Manufacturing Industries Sdn Bhd Johor 1 14 Eastern Pretech (M) Sdn Bhd KL 1 15 Precast Product Sdn Bhd NS 1 16 Setia Precast Sdn Bhd Selangor 1 17 SCID Concrete Manufacturing Sdn Bhd Sarawak 1 18 Sunway Precast Industries Sdn Bhd Selangor 1 19 CMS Concrete Products Sdn Bhd Sarawak 1 1

10 OKA Concrete Industries Sdn Bhd Perak 1 111 E.V. Oilfield Supply And Services Sdn Bhd Melaka 1 112 Binaan Desjaya Sdn Bhd Pahang 1 113 Baktian Sdn Bhd KL 1 114 CSR Building Materials (M) Sdn Bhd Selangor 1 115 P Slabs (M) Sdn Bhd KL 1 116 IBS Prestress Technology Sdn Bhd Terengganu 1 117 Ezidek (M) Sdn Bhd Melaka 1 118 PJDCP Malta Sdn Bhd KL 1 119 HC Precast System Sdn Bhd Selangor 1 120 Sunway Cavity Wall Panel Sdn Bhd Selangor 2 1 121 Jitra Engineering Sdn Bhd KL 1 1

31 8 4 2 4 2 2 2 2 1 2 2

PRODUCTS

TYPE 1

TOTAL

FACTORY LOCATION

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 plants in Kelantan and Perlis.

Precast Concrete Plants

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IBS Component manufacturing

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.

# Name Head officeNo. of

FactoriesS'gor KL Perak T'ganu Kelantan Sabah

1 Cycleworld Corporation Sdn Bhd Selangor 1 12 Boral Plasterboard (Malaysia) Sdn Bhd Selangor 1 13 Saint-Gobain Construction Products (M) Sdn Bhd Selangor 1 14 HLE Precast Sdn Bhd Selangor 1 15 EVG Regional Office Sea Selangor 1 16 MST Marketing Sdn Bhd KL 1 17 Uniplaster Industries Sdn Bhd KL 1 18 UAC Berhad Selangor 1 19 Hume Cemboard Industries Sdn Bhd Selangor 1 110 Perceptive Profile Sdn Bhd Perak 1 111 ISO Marketing And Services Sdn Bhd Terengganu 1 112 IBS Interlocking Brick Sdn Bhd Terengganu 1 113 ID Interlocking Bricks Sdn Bhd Terengganu 1 114 Duralite (M) Sdn Bhd KL 1 115 East Asia Modular Sdn Bhd Sabah 1 1

15 5 1 4 3 1 1

FACTORY LOCATION

TYPE

1A

Innovative, Panel and Block System Plants

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IBS Component manufacturing

# NameHead office

Number of Factories

Column Beam Slab Wall Staircase S'gor Johor

1 PERI Formwork (M) Sdn Bhd KL 1 12 Westform Industries Sdn Bhd KL 1 13 MFE Formwork Technology Sdn Bhd Selangor 1 14 HIFORM(M) Sdn Bhd Selangor 1 15 Transkon Sdn Bhd Selangor 1 16 Plastech Industrial Systems Sdn Bhd Selangor 1 17 EFCO (M) Sdn Bhd Selangor 1 18 Asiaric Contracts Sdn Bhd Selangor 1 19 Fastsave Formwork Trading & Engineering Sdn Bhd selangor 1 110 Fuji Engineering Sdn Bhd Selangor 1 111 LTH Engineering Sdn Bhd Selangor 1 112 Floodlit Enterprise (M) Sdn Bhd Johor 1 113 BHS Plasticply (M) Sdn Bhd KL 1 114 Simple Formwork Construction Sdn Bhd Selangor 1 115 Mya Hitech Sdn Bhd Johor 1 116 TAC System Formwork Sdn Bhd Selangor 1 1

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FACTORY LOCATIONPRODUCTS

TYPE 2

TOTAL

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).

Steel Formwork Systems Plants

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IBS Component manufacturing

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. Zamil Steel Building operates 2 plants in Vietnam

# Name Head officeNumber of Factories

Roof TrusPortal 

F rameS'gor KL Johor Perak Pulau

PinangN.

Sembilan Kelantan Sabah Sarawak

1 Bluescope Lysaght (Malaysia) Sdn Bhd Selangor 1 12 M- Truss Sdn Bhd Selangor 1 13 Kamuja Fabricator Sdn Bhd Selangor 1 14 KUTERA Resources (M) Sdn Bhd Selangor 1 15 Great Allied Engineering Sdn Bhd Johor 1 16 SRT Building System Sdn Bhd Perak 1 17 Juta Steel Sdn Bhd Selangor 1 18 UAC Stell System Sdn Bhd Selangor 1 19 Pryda (M) Sdn Bhd Selangor 1 1

10 Sunsrise Prima Sdn Bhd Selangor 1 111 Dayatera Engineering Sdn Bhd Selangor 1 112 Superspan Stell Sdn Bhd Selangor 1 113 Lavenda Building Systems Selangor 1 114 Tangsa Corporation Sdn Bhd KL 1 115 Lotez Engineering Sdn Bhd KL 1 116 Sarnho Preserver Sdn Bhd KL 1 117 Sdn BhdF Builders Sdn Bhd KL 1 118 Teguh Aluminium & Construction Sdn Bh Johor 1 119 Asia Roofing Industries Sdn Bhd Johor 1 120 Visage Industries Sdn Bhd P.Pinang 1 121 Tong Yong Metal Sdn Bhd P.Pinang 1 122 Brickwell Sdn Bhd Kelantan 1 123 Home Truss System Sdn Bhd Perak 1 124 Bluecsope Lysaght (Sarawak) Sdn Bhd Sarawak 1 125 Bluecsope Lysaght (Sabah) Sdn Bhd Sabah 1 126 Manik Prestasi Sdn Bhd Selangor 1 127 Rolfom Innovation Sdn Bhd 1 128 Zamil Steel Building KL 0

29 Wira Kerjaya Sdn Bhd Selangor 0

27 12 4 3 2 2 1 1 1 1

PRODUCTS

TYPE 3

TOTAL

VIETNAMCHINA

FACTORY LOCATION

Steel Framing System Plants

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IBS Component manufacturing

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.

# Name Head officeNumber of Factories

Roof TrusT imber 

F rameS'gor KL T'ganu Malacca

1 Sunrise Prima Sdn Bhd Selangor 1 12 Dayatera Engineering Sdn Bhd Selangor 1 13 Mitek Asia Sdn Bhd Selangor 1 14 Hong Giap Sdn Bhd Selangor 1 15 Setia Wood Industries Sdn Bhd Selangor 1 16 Woodlandor Roof Systems Sdn Bhd Selangor 1 17 Kamuja Fabricator Sdn Bhd Selangor 1 18 SBF Builders Sdn Bhd KL 1 19 Tangsa Corperation Sdn Bhd KL 1 1

10 Simpang Woodworking Sdn Bhd Selangor 1 111 Pryda (M) Sdn Bhd Selangor 1 112 Shing Huat Rooftruss Sdn Bhd KL 1 113 Sarnho Preserver Sdn Bhd KL 1 114 Pesama Timber Corporation Sdn Bhd Terengganu 1 115 KPMY Roof Builders Sdn Bhd Terengganu 1 116 Boh Huat Chan Timber Product Sdn Bhd Melaka 1 1

16 9 4 2 1

PRODUCTS

TYPE

4

TOTAL

FACTORY LOCATION

Prefabricated Timber Framing System Plants

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IBS Component manufacturing

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.

# Name Head officeNumber of Factories

CMU SOLID

CMU LIGHT-WEIGHT

CMU HOLLOW

CMU INTER-LOCKING S'gor KL Pulau

Pinang Sabah Perak Pahang

1 Intergrated Brickwork Sdn Bhd KL 1 1

2 Zenbes Sdn Bhd KL 1 1

3 Multi Usage Holdings Berhad P.Pinang 1 1

4 Brikform Sdn Bhd Sabah 1 1

5 Exxomas (PG) Sdn Bhd P.Pinang 1 1

6 Binaan Desjaya Sdn Bhd Pahang 1 1

7 CSR Building Materials (M) Sdn Bhd Selangor 1 1

8 Suprafoam Construction Technogies Sdn Bhd Sabah 1 1

9 CKYJ (M) Sdn Bhd KL 1 1

10 The Project Management Shop (M) Sdn Bhd Selangor 1 1

10 2 2 2 2 1 1

FACTORY LOCATIONPRODUCTS

TYPE

5

TOTAL

Blockwork Plants

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IBS Component manufacturing

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.

# NameHead office

No.of Factories

Pc Columm Pc Beam Pc Slab Pc Wall/ Panel Pc Staircase

1 Ibuzawa Corporation Sdn Bhd KL 1

2 Global Prefab System Sdn Bhd KL 1

3 Bumi Harus Sdn Bhd KL 1

4 Pembinaan Era Dinamik Sdn Bhd Selangor 1

5 Creative Precast Technics Sdn Bhd Selangor 1

6 P&N Construction Sdn Bhd Selangor 1

7 Niaga Sari Sdn Bhd KL 1

8 Left -Right Construction Sdn Bhd Selangor 1

9 Pembinaan Punca Cergas Sdn Bhd KL 1

10 Pembinaan Ikhasas-Merak Sdn. Bhd Selangor 1

11 Corporate Builders Sdn Bhd KL 1

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PRODUCTS

TY

PE

6

TOTAL

On-Site IBS Manufacturers

StandardisationIssue

Designers Contractors / Builders/ Owners

IBS Manufacturing Base

Construction Site

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

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

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

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)

Challenges

IBS Value Chain

The challenges faced have remain unchanged despite being repeatedly voiced by the industry stakeholders during surveys, forums and workshops through-out the years…indicates problems need

to be resolved at the root cause level

Skills Issue

118 manufacturers63,977 contractors 3,252 architects 59.304 engineers2,081 quantity surveyors

Designers Contractors / Builders/ Owners

IBS Manufacturing Base

Construction Site

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

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

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

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)

Challenges

IBS Value Chain

The challenges faced have remain unchanged despite being repeatedly voiced by the industry stakeholders during surveys, forums and workshops through-out the years…indicates problems need

to be resolved at the root cause level

Skills Issue

118 manufacturers63,977 contractors 3,252 architects 59.304 engineers2,081 quantity surveyors

Challenges and Lessons Learn Along the Construction Industry Value Chain

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IBS STANDARDISATIONIBS STANDARDISATION

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KomponenStruktur

KomponenKemasan

Bangunan Asas/ ‘Base Building’

1.Komponen Struktur

2.Komponen Kemasan3.Komponen M&E

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Pelaksanaan Katalog IBS Kebangsaan

Consultant

Manufacturer

Contractor

‘Project Owner’

• Penyeragaman Pelaksanaan• Mencetuskan Industri IBS

• Garispanduan Rekabentuk• Rujukan Piawaian IBS• Rujukan MS 1064

• Garispanduan PengilanganKomponen IBS

• Rujukan MS 1064

• Keperluan Kontrak Bangunan• Mencapai IBS Score 70%

Pelaksanaan Projek

KATALOGIBS

KEBANGSAAN

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THE IBS CENTRETHE IBS CENTRE

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PUSAT IBSTINGKAT 1, BLOK E, LOT 8, JALAN CHAN SOW LIN, 55200 KUALA LUMPUR

TEL: 03-9281 6909 FAX: 03-9281 5870

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Jalan Chan Sow Lin

Entrance 1

Entrance 2

Jala

nC

hera

s

Jala

nLoke

Yew

Fasiliti Pusat IBS

Product Testing Facilities

IBS Village

Existing IBS Gallery& Administration

IBS Component Galleries

Conventional Hall

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5 Cores

5 Main Functions IBS Centre

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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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• IBS Status Consultants

• IBS Status Contractor

• IBS Status Manufacturer

• IBS Status Installers

Product & Service IBS : Verification & Certification

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Penyediaan Bahan, Dokumen, Sumber oleh Pusat IB

• 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

29 Penerbitan

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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

Source : Construction Industry Master Plan, 2006-2015

Conclusion

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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.mywww.cidb.gov.my

ibs@cidb.gov.myibs@cidb.gov.my