Definition:-

“ CONSTRUCTION METHOD/SYSTEM which its components been produced/prefabricated in CONTROLLED situations ( on site or factory)

TRANSFERRED and FABRICATED in construction works by minimum on site workers”

“Merupakan SISTEM / KAEDAH PEMBINAAN yang mana komponennya dihasilkan di dalam keadaan TERKAWAL (dikilang atau ditapak bina), DIANGKUT dan

DIPASANG dalam kerja pembinaan dengan menggunakan pekerja di tapak yang minima”

FACTORY TRANSPORT FABRICATE

WHAT IS IBS?

BUILDING

ON SITE

CONVENSIONAL METHOD CONSTRUCTION

CONSTRUCTION MATERIAL

Concrete

Brick

Steel Bar

Wood

Equipments

Building

ON-SITEOFF-SITE

IBS CONSTRUCTION

Construction Components

Wall panel

Wood Frame

Precast staircase

Wood brace

Construction Materials

Concrete

Brick

Block

Wood

MAIN IBS COMPONENTS

Roof Brace

Beam

Slab

Column

Staircase BUILDING 5 Types IBS

CONSTRUCTION METHOD COMPARISON

0 % IBS

Convensional Method

100 % IBS

IBS Method

CONVENSIONAL METHOD IBS METHOD

COMPARE !!!!!!!!

PRECAST GROUND BEAM

CONVENSIONAL METHOD IBS METHOD

COMPARE !!!!!!!!

Formwork

IBS TYPES

Precast Concrete Steel Frame

Wood Frame Block Other Innovatif System

2 3

4 5

PC columns, beams, slabs, 3D-components (balconies, staircases, toilets, lift chambers, box girders, etc)

1: PRECAST CONCRETE SYSTEM

2

2: FORMWORK SYSTEM

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

3 : STEEL FRAME SYSTEM

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

4: WOOD FRAME SYSTEM

Timber frames, pre-fab timber

roof trusses, etc.

5 : BLOCK SYSTEM

Interlocking concrete masonry unit (CMU), lightweight concrete blocks, etc.

6 : NEW INNOVATIVE SYSTEM

DEVELOPMENT IBS IN MALAYSIA

2004 2005 2006 2007 2008 2009 20152003

MS 1064: Modular Coordination sebagai panduan dalam merekabentuk bangunan

IBS Roadmap 2003-2010

Manual for IBS Content Scoring Diterbitkan

Pekeliling Perbendaharaan pada 25 Julai 2005

“Penggalakkan”

Pekeliling Perbendaharaan pada 31 Oktober 2008

“Mandat”

1999

IBS Strategic Plan 1999

IBS Roadmap Review 2008-2010

2010

Malaysia IBS International Exhibition ’06 (MIIE06)

Diluluskan oleh Kabinet

Construction Industry Master Plan2006-2015

Malaysia IBS International Exhibition ’09 (MIIE09)

IBS Roadmap

2011-2015

2001Manual for IBS Content Scoring CIS18 2010: Diterbitkan

Projek Perintis IBS: Flat Pekeliling,KL & Flat Riffle Range, P.Pinang

1966

Malaysia IBS International Exhibition 2011(MIIE’11)

2011

Diluluskan Jemaah Menteri Kabinet pada 9 Julai 2010

StandardisationIssue

Designers Contractors /

Builders/ OwnersIBS 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/ OwnersIBS 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

IBS Village

Terrace House ApartmentBungalow

USED OF IBS SYSTEM

• All building components such as wall, floor slab, beam, column and staircases are mass produced either in factory or at site under strict quality control and minimal on site activities

• Mechanization of the building processes

• Example of completed building in Malaysia HUKM, university Hospital, Selayang Hospital, Kuala Lumpur Tower, IKEA Damansara

Timber Frame

Steel Formwork

Steel Frame

Precast Concrete

Blockwork

Industrialised Building System

• Masonry Unit

• Lightweight Blocks

• Pre-fab timber

• Beam

• Column

• Steel

• Aluminum

• Framing

• Panel

• Box

Structural Category of IBSBased on CIDB

Group 1: Pre-cast Concrete Framing, Panel and Box Systems

• Includes precast concrete columns, beams, slabs, walls.

• 3 D components e.g. balconies, staircases, toilets, lift chambers, refuse chambers.

• Lightweight precast concrete and permanent concrete formworks.

Balcony

Beams

PRE- CAST CONCRETE

COMPONENTS

Group 2: Steel Formwork Systems

• E.g.: tunnel forms, tilt-up system

• beams/columns molding and

• Permanent steel formworks (metal decks)

Tilt-up system and permanent steel formworks

Group 3: Steel Framing Systems

• Steel framing system e.g. steel trusses, columns, beams and portal frame system

Group 4: Prefabricated Timber Framing Systems

• Prefabricated timber framing systems consists of prefabricated timber trusses, beams and columns.

Group 5: Block Work Systems

• Block work system includes interlocking concrete masonry unit (CMU)

• Lightweight concrete blocks

Group 6 : NEW INNOVATIF SYSTEM

IBS AS A SUSTAINABLE CONSTRUCTION

• Sustainable construction enable to:-

I. Save energy and resources, recycle materials & minimize the emission of toxic substances.

II. Harmonies with the local climates, traditions, culture & the surrounding environment.

III. Able to sustain & improve the quality of human life whilst at local & global levels.

IV. Saving and increase workplace productivity.

ADVANTAGES OF INDUSTRIALISED BUILDING SYSTEM (IBS)According to CIDB (2003), compares to conventional construction

method, the IBS has the following advantages:

i. Less construction time

• IBS requires less construction time because casting of precast element at factory and foundation work at site can occur simultaneously and the work at site is only the erection of IBS components. This leads to earlier occupation of the building.

ii. Cost savings

• The formwork of IBS components are made of steel, aluminum or other materials

that allows for repetitive use and this leads to considerable cost savings.

iii. Saving in labour

• When the IBS components are produced in factory, higher degree of utilization of machine is permitted and the use of labour will be reduced and lead to saving in labour cost.

iv. Less labour at site

• The use of IBS will reduce the construction process at site and consequently reduce the number of labour required at site.

v. Optimized use of material

• The utilization of machine during the production of IBS components lead to higher degree of precision and accuracy in the production and consequently reduce material wastage.

vi. Higher quality and better finishes

• An IBS component have higher quality and better finishes due to the careful selection of materials, use of advanced technology, better and strict quality assurance control since production in factory is under sheltered environment.

vii. Construction operation less affected by weather

• Faster project completion due to rapid all weather construction. The effects of weather on construction operation are less due to the fabrication of IBS components is done in factory while at site is only erection of the components.

viii. Flexibility• IBS provides flexibility in the design of precast element so that

different systems may produce their own unique prefabrication construction methods.

ix. Increase site safety and neatness• Utilization of IBS components leads to less construction process

especially wet work at site. This will lead to the neater site condition and increase safety.

x. Environmental friendly• The use of IBS will decrease the using of timber formwork on

construction project

DISADVANTAGES OF IBS

i. High initial capital cost• The initial capital cost of IBS is usually high. The initial cost

including the cost of constructing the factory, casting beds and support machinery. The cost effectiveness can only be achieved when undertaking large projects.

ii. Problem of joints• Water leakage is often the major problem in building constructed

using IBS. This problem is more obvious in Malaysia where raining occur rapidly through out the year.

iii. Sophisticated plants and skilled operators• The prefabrication system relies heavily on sophisticated plants,

which have to be well coordinated and maintained by skilled operators. Breakdown in any one section would hold-up the entire production line.

iv. Site accessibility

• Site accessibility is one of the most important factors of the implementation of IBS.IBS requires adequate sit accessibility to transport IBS components from factory to the site.

v. Large working area

• Building construction using IBS requires a large working area for the factory, trailers, tower-cranes and storage for the IBS components. Besides, most construction sites especially in cities are often congested and unable to provide the area required.

Time

IBS Penetration

high%

1999

Fast Track

option for

government

projects

Sporadic developments

using IBS

Policy Driven

1970-s 2005 2008

Dayabumi

Pekeliling

Flats

low

IBS

Strategic

Plan

Treasury

Circular

2005

Treasury

Circular

2008

today

70%

scoring for

all RM10m

projects

2015

50%

scoring for

all RM10m

projects

2012

Policy Driven

2020

IBS Track for the Public Sector

The Government sector will enforce the use of IBS components by 70% for projects worth RM10 million and above, as in the Surat Pekeliling Bil 7./2008 for the period of implementation IBS

Roadmap 2011-2015

Policy (Private Sector) – score mean achievement of IBS– incentive of IBS

Government Sector

Private Sector

58 IBS Projects

Applied for Levi

Exemption

FUTURE DEMAND ON IBS IN CONSTRUCTION INDUSTRY (source CIDB)

THE HOUSE OF IBS

High Quality Building and Accurate Completion Time

Sustainable policy and political will

IBS integration in Construction Industry Network

Comprehensive Standardization(Policy, Administration and Legal)

Dev

elo

pm

en

t o

fIB

S P

eop

le

Penggunaan Tenaga Kerja Yang Kurang

Penjanaan Kewangan

Berterusan

Ince

nti

ve

Gre

en

Te

chn

olo

gy

Pre

fer

Qu

alit

y In

A

Pro

ject

C

on

trac

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Re

sear

ch a

nd

D

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RESTRUCTURING ROADMAP IBS

Objective

MainComponent

Basic