A rticle

Industrialised Building System:

Current Shortcomings And The Vital
Role Of R&D
By Kamarul Anuar Mohamad Kamar, Ir. Dr. Zuhairi Abd. Hamid, Mohd Khairolden Ghani and Ahmad Hazim
Rahim, Construction Research Institute of Malaysia

An early effort by the Government of Malaysia to promote usage of Industrialised Building System
(IBS) and develop an Open Building System (OBS) concept as an alternative to conventional and
labor intensive construction method has yet to make a headway. Although members of the industry
are open to the idea, a major portion of the industry stakeholders are indifferent, perhaps due
to resistance towards change, insufficient information and lack of technology transfer method to
support feasibility of change to IBS. In this case, it has proven that it is difficult to introduce new
technologies and method in the construction sector when compared to other sectors. According to
Hervas et. al (2007) construction sector is known as a traditional sector that can be characterised as
reluctant and even resistant to change.

I
BS is defined as a construction for every aspect of construction to a analysis and the development of
system in which components are system that make use of manufacturing standardized components.
manufactured in a factory, on or production in order to minimize
off site, positioned and assembled resource wastage and enhance value History of IBS in Malaysia
into structure with minimal additional for end users. Junid (1986), identified
site work (CIDB, 2003). Dietz, A.G.H IBS as a process by which components IBS began in early 1960s when Ministry
(1971) earlier defined IBS as total of a building are conceived, planned of Housing and Local Government
integration of all subsystem and and fabricated, transported and erected of Malaysia visited several European
components into overall process fully at site. The system includes a balanced countries and evaluate their housing
utilizing industrialized production, combination between software and development program. (Thanoon et
transportation and assembly hardware component. The software al, 2003). After their successful visit
techniques. Lessing et al, (2005) defined element include system design, which in the year 1964, the Government
IBS as an integrated manufacturing and is a complex process of studying the had launched pilot project on IBS
construction process with well planned requirement of the end user, market to speed up the delivery time and
organization for efficient management,
preparation and control over resources
used, activities and results supported
by the used of highly developed
components. Trikha (1999) defined as a
system in which concrete components
prefabricated at site or in factory are
assembly to form the structure with
minimum in situ construction. IBS is
also defined as a set of interrelated
element that act together to enable
the designated performance of the
building (Warszawski, 1999). Parid
Wardi (1997) defined IBS as a system
which uses industrialised production
techniques either in the production
of components or assembly of the
building or both. Esa and Nurudin
(1998) asserted that IBS is a continuum
beginning from utilizing craftsmen LRT station

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A rticle

built affordable and quality houses.

Nearly, 22.7 acres of land along Jalan
Pekeliling was dedicated to the project
comprising seven blocks of 17-storey
flats (3,000 units of low-cost flat and 40
shop lot). This project was undertaken
by Gammon/ Larsen Nielsen using
the Danish System of large panels in
a pre-fabricated system. In 1965, the
Government of Malaysia launched a
second project, a six block of 17-storey
flats and three blocks of 18-storey
flats at Jalan Rifle Range. The project
was awarded to Hochtief/ Chee Seng
using French Estoit System (Din, 1984).
Between 1981 and 1993, PKNS a state
Government development agency
acquired pre-cast concrete technology
from Praton Haus International based
in Germany to build low-cost houses
and high cost bungalows in Selangor
(National IBS Survey, 2003). Today in the
Malaysian construction industry, the
use of IBS as a method of construction Bukit Jalil Sport Complex
is evolving. More local manufacturers
have established themselves in the each beginning with ‘M’. They are a number of implementation snags
market. As a result pre-cast, steel Manpower, Materials, Management, were identified as being potential
frame and other IBS were used as Monetary, and Marketing. The inputs hurdles to the implementation of the
hybrid construction methods to build are then divided into elements and Roadmap. These include the following
national landmarks such as Bukit Jalil the activities to be implemented for which have been identified by IBS
Sport Complex, LRT and Petronas Twin each element were then identified Steering Committee:
Tower. It was reported that at least and included into the time span of
21 manufactures and suppliers of IBS the Roadmap in order to achieve the ● Development of standard plans and
are actively promoting their systems mission within the stipulated time- standard component drawings for
in Malaysia. IBS move to the next frame. The content of this roadmap common use,
step of the development through the is focused towards achieving the ● Apprentice and on-the-job training

establishment of IBS Centre at Jalan industrialisation of the construction in the area of IBS moulds and casts,
Chan Sow Lin, Cheras, Kuala Lumpur. sector and the longer term objective and assembly of components,
The obligation to implement IBS of Open Building Systems concept. It ● I B S t e s t i n g a n d e v a l u a t i o n

serves both to improve performance has been five years since the launching programme,
and quality in construction, as well as of the Roadmap and more than ● Vendor development programme,

to minimize dependency on unskilled half-way the target of industrialising ● Readiness of designers and

foreign labour in the construction
market.
Shortcomings of IBS
CIDB published the IBS Roadmap 2003-
2010 which detailed the needs and
requirements of Malaysian construction
industry. This roadmap was endorsed
by Cabinet on October 29, 2003. The
Roadmap is a comprehensive document
that divided the IBS programme into
the five main focus areas that reflect the
inputs needed to drive the programme,
construction. It is pertinent to examine
the progress and how close we are
to the completion of the mission.
More importantly, it is imperative to
evaluate whether the implementation
of the roadmap has met the market
response to the IBS programme. Most
policy issues have been resolved
and implemented, while all relevant
documents required to support the
programme have been developed. In
particular, activities under the charge
of CIDB are all meeting their deadlines.
Notwithstanding these achievements,
consultant practices, quality control,
production of standard components
in the field of IBS.
Realising the implementation of IBS is
still to make headway, CIDB through
Construction Research Institute of
Malaysia (CREAM) has taken the
initiative to conduct three workshops
for the industr y. After lengthy
deliberation with stakeholders, it was
concluded that the factors contributing
to the delay of IBS implementation are
as follows:

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● It is not popular choice among
design consultants
● L a c k o f k n o w l e d g e a m o n g
designers
● The need for mindset change with
proper education
● Costing – chicken and egg
problem
● Private sector adoption
● Proprietary systems make it hard to
be adopted by designers
● Poor quality products
● Joints are not standardised making
it hard to design as the designs are
fixed by a particular manufacturer
● Insufficient push factor
● Lack of technical know-how e.g.
structure
● Volume and economies of scale
● The monopoly of big boys,
limiting opportunities to
Bumiputra contractors. Require
Petronas Twin Tower
appropriate training for Bumiputra
contractors
● Low off-site manufacturing of
construc tion components to
guarantee quality, mechanization
and standardization
● To consider IBS design that promote
energy conservation
● Sustainability of construction
industry, Government to lead
during downturn
● Require on-site specialised skills
for assembly and erection of
components
● Lack of special equipment and
machinery which hamper work.
Require more local R&D, support
services, technologies and testing
labs
● Insufficient capacity building for
contractors to secure project in
construction (G1-G7)
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2nd Quarter 2007
● Below 10% IBS construction
involvement by Bumiputra
contractors
● Mismatch between readiness of
industries and IBS targets by CIDB
● The cost depends on volume and
types of projects
● Ear thquake resistant design
pertaining to IBS components (e.g
joint system, seismic performance
and design guidelines)
● Earthquake protection of IBS
buildings (base isolation and rubber
damping systems)
● No standard joint developed for
building components
The Way Forward
CIDB believes that R&D is the way
forward for developing IBS. The
R&D themes and topics for IBS are
aligned to the requirements of the
IBS Roadmap 2003-2010. Although
the initiatives in IBS are lead by
CIDB, participation from contractors,
consultants, academia, companies
and research institutes are critical.
It is a daunting task as 2010 is just
around the corner. The processes
and mechanisms to accomplish the
target depend on the integration
and acceptance of IBS by players.
The coming three years will be very
challenging. A strategic approach will
be the way forward. As the R&D arm
for CIDB, CREAM’s R&D output will
geared towards industry’s application
and requirements.
A combination of integrated
approaches and long term strategic
partnering with stakeholders tackling
specific agenda on IBS’ 5M strategies
are the way forward. Well co-ordinated
and planned R&D themes and titles
discussed in earlier section have to
be implemented simultaneously with
all players. CREAM shall take the
following actions as a prerequisite to
expedite the success of the roadmap
implementation with respect to IBS:
● A long term and strategic approach
of conducting research on IBS shall be
established,
A rticle
● The involvement of universities,
companies, organisations and research
institutes right from the onset of any
IBS R&D project,
● Participation and inclusion of IBS in
JKR building design, i.e. JKR IBS Design
must be incorporated in its Rekabentuk
Bangunan Piawai for Government
quarters, schools and Government
administrative offices. (CREAM should
discuss this matter further with JKR on
any issues related to R&D).
● Malaysian standard joints for IBS
(wet or dry) must be designed and
made available for use by industry,
● CREAM initiatives to lead Centre of
Research Excellence on IBS and act as
One Stop Centre for R&D are critical as
this moves will consolidate the effort
to centralize and identify issues and
problems first hand from industry,
● The formation of R&D laboratory
and CORE for IBS is urgent and CREAM
should initiate and take the lead,
● CREAM is to apply for double
deduction status to expedite
participation from private entities as
they will also benefit in getting tax
rebates when contributing research
funds,
● Open Building System must
be competitive in terms of cost,
performance and quality as compared
to proprietary system and conventional
methods in order to be sustainable in
the construction market,
● Not reinventing the wheel on R&D
but to focus on IBS applied research,
● Soft issues related to IBS
such as marketing, social impact,
involvement of Bumiputra contractors
in vendor development programme as
highlighted in the roadmap should be
taken on board at the early stage,
● A complete comprehensive study on
IBS solutions encompassing the entire
value chain will ensure its success.
These shall include verification, will add value and expedite the
validation and certification of process implementation process.
on IBS components, fabricator,
factory, erector and related skills of
Acknowledgement
specialization,
We would like to thank Malaysian
● A technology transfer model via
IBS Steering Committee Session
knowledge management adapted
2003-2005 and IBS Centre for their
from EU, Japan and Singapore
support and assistance.
best practices in implementing IBS
References
CIDB (2003), IBS Roadmap 2003-2010, CIDB publication
CIDB (2003), Construction Industry Master Plan 2006-2015, CIDB publication
CREAM (2007), Strategic Management of R&D in IBS unpublished documentation
by CREAM
CREAM (2007), Workshop on aligning R&D themes and titles to the requirement
of construction industry unpublished report by CREAM
CIDB, (2003), National IBS Survey, 2003, CIDB publication
Dietz, A.G.H (1971) as stated in Jaafar, S., et al (2003), Global Trends in Research,
Development and Construction, proceeding of The International conference
On Industrilised Building System (IBS 2003), CIDB
Din, (1984), Industrilised building and its application in Malaysia, proceeding
on Seminar on Prefabrication Building Construction.
Esa and Nurudin (1998), Policy on industrilised building system, report on
qollocium on industrilised construction system, Kuala Lumpur.
Hervas et. al (2007), as stated in Kazi, S., (2007), Open Building Manufacturing
– Core Concept and Industrial Requirement, Manubuild Consortium.
Junid, S., (1986), Industrilised Building System. Proceeding of UNESCO/FEISEAP
regional workshop.
Lessing et al, (2005), as stated in Kazi, S., (2007), Open Building Manufacturing
– Core Concept and Industrial Requirement, Manubuild Consortium.
Parid Wardi (1997), as stated in Jaafar, S., et al (2003), Global Trends in Research,
Development and Construction, proceeding of The International conference
On Industrilised Building System (IBS 2003), CIDB
Thanoon et al, (2003), An assessment of the industrilised building system in
Malaysia, Proceeding on IBS Seminar, UPM, Malaysia
Trikha (1999), Industrilised building system: prospect in Malaysia. Proceeding of
World Engineering Congress, Kuala Lumpur.
Warszawski, (1999), Industrilised and automated building system, Technion-Israel
Institute of Technology, E & FN Spon
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