IBS DIGEST Issue 02/2007 Construction Industry Development Board (CIDB) IBS: CURRENT CHALLENGES AND THE VITAL ROLES OF R&D ‘Sumbangan: Zuhairi Abd. Hamid, Mohd Khairolden Ghani, Anmad Hazim Abdul Rahim, and Kamarul Anuar Mohamad Kamar; Construction R PP One of the challenges facing _our constuction industry is the acute shortage Of construction workers. This, together wih the social problems associatod with foreign workers, further aggravates the situation (Gue, 2007). As such, the Industalised Building System (5S) {5 introduced to reduce our ‘dependency on foreign workers. Nevertheless, tearly effort by the government of Malaysia to promote usage of IBS as an alternative to conventional and labour intensive consiruction ‘method has yet to make headway. Athough ‘members ofthe Industry are open to the idea, '2-major portion of the Industry slakeholders ‘are indiferent, perhaps due to resistance towards change, insufficient information and lack of technology transTer methods to support, feasibility of change to IBS. In this case, i has proven that itis dificult to introduce new technologies and methods in the construction sector when compared to other sectors. Aevording to Hervas (2007), construction sector ls known as tadhonal sector that can be characterised as reluctant and even resistant to change. This paper discusses the Current implementation of IBS in Malaysia, Its challenges and the way forward To date, there has been no one commonly-accepted for agreed definition of IBS. However, the authors have gathered @ few definitons by researchers who studied Into this area previously, thatisreflectedtotnolBS ‘concept accepted by the Malaysian construction. BS is defined as a construcion system which components are manufactured ina factory, on or off site, positioned and assembled into structures with minimal ‘aditonal site work (CIDB, 2003). Dietz (1971) earlier defined 13S as (otal integration fof all subsystem and components into overall process fully uilizing industalsed production leansportation and ‘assembly techniques. Parid (1997) defined 18S fas a systom which use industaised production technique etherin the production of component cor assembly of the bulding or both. Lessing et al (2008) defined 18S as an integrated ‘manufacturing and construction process with well planned organisation for efficient management, proparation and control over resources used, actives and results supported by the used of highly developed components, “Tika (1999) defined IBS as a system in which ‘conerete components prefabricated al site or in factory are assembled lo form the structure ‘with minimum in sity construction. IBS also ‘dofined ae a set of interelate element that act together lo enable the designated performance of the bulking (Warszawski, 1998). Esa fand Nurudin (1998) asserted that IBS is a Centinuum Beginning from utlizing craftsmen forevery aspectof construction toa system that make use of manufacturing production in order to minimize resource wastage and enhance value end users. Juni (1986), identified IBS as process by which components of bulding are ‘onesived, planned and fabricated, transported land erected at site. The system includes balanced combination between sofware and hardware components. The software element includes system design, which is complex process of studying the requirement ofthe end tise, market analysis and the development of Standardised components Local 18S industty began in early 1960's when Ministry of Housing and Local Government of Malaysia visited several European countries and evaluate their housing development program. (Thanoon eta, 2003). ‘After their successful Vsit in tho yoar 1964, the government had launched plot project, fn IBS 10 speed up the delvery time and built affordable and quali houses. Nearly 22.7 acres of land along Jalan Pekoliing was, dicated to the project; comprising 7 blocks of 17-storey flats (3000 unit of low-cost fats ‘and 40 shop lots. This project was. taken by Gammon’ Larsen Nielsen using Danish ‘System of lage pancls of prefabricated system. In 1985, tho government of Malaysia, launched the second project, 6 blocks of 17- slorey flats and 3 blocks of 18-storey fats at Jalan Rife Range. The project was awarded to Hochtiet/ Chee Seng using French Estot System (Din, 1984). Botween 1981 and 1993, PKNS, a stale government development agency acquired German pre-cast concrete technology from Praton Haus International to build low-cost houses and. high-cost bungalows in Selangor (CIDB, 20038). In our construction industy today, the use of BS as @ method of construction is evolving. More local ‘manufacturers have established themselves in the markot.AS a result pre-cast concrete, steel ‘and other IBS were used as hyorid construction systems to build national landmarks such as Bukit Jalil Sport Complex, LRT and Petronas Twin Towers. It was reported that at least 24 of various manufactures and suppliers of IBS. ‘are actively promoting ther system in Malaysia (Thanoon ot al, 2003). 18S moved to next step ‘of the development through the establishment (Of IBS Centre initiated by C108, at Jaian Chan. Sow Lin, Cheras, Kuala Lumpur The obligation to implement IBS strategies and activi from this centro serves bath io improve performance ‘and quali in construction, and aso ta minimize the dependency of unskilled foreign labours flooding the construction market40 The Challenges CCIDB nas published 18S Roadmap 2003. 2010 which enaled the needs and requirement ‘of Malaysian construction industry. This foadmap was endorsed by Cabinet on 25th (October 2003, Theroadman isa comprehensive document that divides the IBS programme into five main focus areas that reflect the inputs needed to arve the programme. They are Manpower, Matorials, Management, Monetary ‘and Marketing (CIDB, 2003a). The inputs are then divided inlo eloments and the acbviies to be implemented for each element are then ienlified and inckuded into the time span of the roadmap in order to achieve the mission ‘within the stipulated time-frame. The content of this roadmap is focused towards achieving the industriaisaion of the constuction sector and the longer term objective of Open Building concept. Ithas been five years since the launching of the rosémap and more than halF-way through the mission of industaising constructon (Hussein, 2007). tis now pertinent to examine the progress and how close to the complation of the mission to dale. Moe importantly ti imperative to evaluate wheter the implementation of the roadmap has met the market reaponse to the IBS programme 50 far. Mest policy issues have been resolved {and implemented, while all retevant documents fequlred to support the programme have een developed. Notwithstanding these ‘achievements a number of implementation ‘snags were identified as baing potenta hurdles {a the full implomeniation of tho roadmap. ‘These include the folowing which have been identified by IBS Steering Commitee 2003- 2008 (Hussein, 2007): + Development of standard plans and standarc component drawings for common use, * Apprentice and on-the-job taining in the area Of moulds and casts, and assembly of ‘components, "IBS testing and evaluation programmo, + Vendor development program, + Reaciness of designers and consultant practices, quay contol. production of Standard components inthe field of IBS. Realising the implementation of IBS is sil lo make headway, CIDB through its research frm, Consiructon Research Insitute of Malaysia (CREAM) has taken tho initiative from the problem Mlentfied eater and has Conducted three workshops session with the Industry between 2006 and 2007. After a lengthy deliberation with the stakeholders, it was concluded thal the factors centbuting to the dolays of IBS implementation are as follows (CREAM, 2007) + The needs of mindset chenge and providing proper education, * Costing ~ chicken and egg problem. + Private sector adoption. + Proprietary eystems - making it hard to bo adopted by designers, Poor qualiy products. + Joints are not standardised - making ithard to ‘design as the design will ave to be fixed to a particular manufacturer + Insffciont push factor. + Lack of technical know-how @ 9. structures. + Volume and economy of scale. “The monopaly of big boys limiting oppertunitios {o Bumipuira contractors. Requires appropriate traning for Bumiputra contractors. + Low offita manufacturing of construction ‘componentsio guarantee quality, echanisation and Standardisation, *To consider IBS dosign that promote energy conservation, = Sustainability of construction industiy, ~ govemment to load during downturn. + Require onsite specialised skis for assembly ‘and erection of components * Lack of special equipments and machinery which hampered work Require more tocal R&D, suppor services, technologies and testing labs + Insufficient capacity building for contractors to secute project in construction (G1-G7). * Under 10% IBS construction involvement from Bumiputra contractors. + Mismatch between readiness of industry and IBS targets by CIDB, + Earthquake resistant design peraiaing to IBS components (0. jointing system, setemic performance ane design guidelines), 5.0 The Way Forward ‘The establishment of CREAM should be seen ‘a8 sicnificant development inthe structure ‘of R&D, which was previously al very formative ‘stages rather organizational ad-hoc and often ‘confusing. CREAM can be assigned a task of ‘managing the IBS research. ‘The RAD thomes and tops for IBS identified through series of workshops organized by CREAM are aligned to the requirement of BS Roadmap 2003-200 (CIDB, 20032). The Inlatives in 18S, though ead by CIDB, require Partcipation from contractors, consultants, Universities, companies and research institute The oblgaton to implement IBS serves Concurrent both to improve and quality in construction: and also to minimise the dependency of unsklled foreign labours flooding the construction market itis a daunting task a5 2010 is just around the comer. The process and mechanism fo achieve the target depend on the integration and acceptance of the players towards IES. Three years ahead wil | be a challenging one. A strategic approach val be the way forward, As the RED arm for CIDE, ‘CREAN's RAD output wil be geared towards Industy's appication and requirements. ‘CREAM shall take the folowing actions es @ ‘pre-requisite fo expedite the success of the roadmap implementation in respect to RAD in 1BS (Ham ot al, 2007) + A long term and strategic approach Of conducting research on IS shall be ‘established, + InvoNement of universes, companies, organizations and research institutes fight from the onset of any 18S RED projects, ‘+ Participation and inclusion of 18S in JKR building design, ie, JKR IBS Design must bo incorporated in. its Rekabentuk Bangunan Fiawai for government quarters, schools and ‘Government administrative offices. (CREAM ‘Should discuss this matter furtner wath KF on ‘any issues related to R&D). + Malaysian standard joints for BS (wot ordry) ‘must be designed and made avaiable for uso by the industry, + CREAM intatves tolead Centre of Research Excellence (CORE) on IBS and act as One ‘Stop Genie for R&D are ciical as this move wil consolidate the efor to centralise and abla oo to idonify issues and problems frst hand from - the industry, + The formation of RD laboratory acting as CORE for IBS is urgent and CREAM should Iniate and take the lea, + CREAM is to apply for a double deduction Salus foundation to expedite. participation ‘rom private entes ae thay wal aleo in rotum be benefited in geting tax rebates whon Contibuting research fund othe industry, + Open Bulding System must be competitive In terms of cost, performance and quailty 2s compared to Proprietary system and Conventional methods inorderto be sustainable inthe construction market, + Noteeinventing the whe! on RED butto focus (on IBS eppled research,+ Soft issues related to IBS such as marketing, ocial impact, involvement of Bumiputera Contractors in vendor development program as highitghted inthe roadmap should be taken on boatd right atthe eaty stage, + A-complete comprehensive study on 18S solutions encompassing the entra valve chain wil ensure ifs success. These shall Include veritcabon, validation and cetication ‘of process en IBS componente, fabricators, factories, erectors and elated ekils of specialisation, + A technology transfer model via knowledge management adapted from EU, Japan and Singapore best practices in implementing IBS will adé value and expedite the implementation process. ‘Acombination of integrated approach and long, {erm strategic partnering among stakeholders tackling specific agenda on IBS 5M strategies fare the way forward. A well coordinated. Planned R&D themes and tiles discussed jn previous section nave to be implemented Simultsnecusly with all players mentioned earlier in synergic and strategic way. ‘The aulhors would like to soknowiedge the following commitiees fr their contrbution: 1. 18S Steering Committee Session 2003- 2008 2, Consiuction Technology Development Division, CIB 3.1BS Cent, Cheras, Kuala Lumpur 4, Paricipants who had attended workshop enitted 8) Workshop on Aligning R&D Prionty Area fo CIMP 2008-2015, 28th -28th May 2008 fat Guoman Resort, Por Dickson, "Negeri ‘Sembilan. ) Workshop on Aligning R&D Thomes and Tiles to the Requirement of Construction Industry, 2181 22nd Apri 2007, Avion Vilage Resort, Port Dickson, Negeri Sembilan. Construction Industry Development Board (CiDB), 2003), Industralsed — Bulaing Systems (IBS) Roacmap 2003-2010, CIOS Malaysia, Kuala Lumpur Construction Industry Development Board (CIDB), (20026), National IBS Survey 2003, CCIDB Malaysia, Kuala Lumpur. Construction Research Institute of Malaysia (CREAN) (2007), Workshop on Aligning R&D Themes and Tiles to the Requirement of Constnicion Industry, 21st -22nd Apr 2007, ‘Avilion Vilage Resort, Port Dickson, Negeri Sembilan (craft report) Dietz, AGH. (1971), Global Trends. in Research, Development and Construction, Proceeding of the International Conference fn Indusiraised Building System (IES 2003), CCIDB Malaysia, Kuala Lumpur, Din, H. (1984), Indusrlised Building and Its Application inMalaysi,Proceedingon Seminar (on Prefabricaton Building Construction, Kuala Lumpur Esa, H. and Nurudin, MIM_ (1998), Polley fon Industraised Bulding System, Report fn Collogium on Incustialeed Construction ‘System, Kuala Lumpur Guo, 8. $. (2007), Bridging the Gap Between R&D and Construction Industy, Keynote ‘Address at Construction Industry Research ‘Achievement iniomatonal Conference, CIDB, WTC, Kusla Lumpur Hamid, 2, Mohamad Kamar, K.A., Ghani, MX, ‘Abdul Rahim, AH. 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