The document outlines the IBS Roadmap 2003-2010 which aims to promote the industrialization of Malaysia's construction sector. Key points include: - The roadmap was endorsed by the Cabinet in 2003 to provide a blueprint for achieving industrialized construction and open building concepts. - It identifies strategies across several areas including manpower, materials, management, monetary incentives, and marketing to promote greater IBS usage. - Targets include increasing IBS usage in government projects to 70% by 2008 and providing incentives for residential projects using at least 50% IBS. - Case studies demonstrate how IBS can help complete projects faster through off-site prefabrication of building components.

1. INDUSTRIALISED ofINDUSTRIALISED of
CONSTRUCTION SECTORCONSTRUCTION SECTOR
THROUGHTHROUGH
IBS ROADMAP 2003-2010IBS ROADMAP 2003-2010
11 JULY 200611 JULY 2006
Construction Industry Development Board Malaysia (CIDB)Construction Industry Development Board Malaysia (CIDB)
Rozaiman HassanRozaiman Hassan

2. MMCMMC
Modern MethodModern Method
ConstructionConstruction
OFFSITEOFFSITE
IBSIBS
Industrialised Building SystemIndustrialised Building System

4. Part 3 :
The Way Forward
Part 1 :
The Current Scenario of
Malaysian Construction Industry
Part 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
Conclusion
Introduction
Part 4 :
Case Study

5. IBS ROADMAP 2003-2010
• On the 29th Oct 2003, the
Cabinet has endorsed a
document – IBS
RoadMap 2003-2010
Introduction

6.  IBS Roadmap 2003-2010 endorsed by the
Cabinet on 29th
. October 2003
 the blueprint document towards achieving the
Industrialisation of the construction sector and
the longer term objective of Open Building
Concept.
IBS ROADMAP 2003-2010
Introduction

7. IntroductionPart 1 :
Implementing the Roadmap
Cabinet
Ministry of Works
[Inter-Ministry coordination committee]
[Chaired by : KSU KKR]
Ministries Agencies
CIDB
Implementation
Coordinator/secretariat IBS Steering Com.
Stakeholders
Policy

8. Poor Site ConditionPart 1 :
The Current Scenario of
Malaysian Construction Industry
 Messy sites
 Poor S & H
 High wastage
 Labour intensive
 Low quality
 Delays

11. SO WHAT IS
CONSTRUCTION
ACTUALLY??
DIRTYDIRTY
DIFFICULTDIFFICULT
DANGEROUSDANGEROUS

12. “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”
DefinitionPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

13. Processing
of steel
Assembly
of floor frame
Assembly of
ceiling frame
Assembly of
sidewall frames
Assembly of
structural unit
Attachment of
exterior walls
Application
of insulators
Attachment of
interior walls
Incorporation of
kitchen facilities
Incorporation of
bath and sanitary
facilities
Final inspection
Packing
Shipment
Delivery
Installation
Major production process
- Manufactured house (Sekisui)

14. ConceptsPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

15. ConceptsPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

16. UsagePart 2 :
Promoting Industrialized Building Systems (IBS) – Simplifying
Construction
FIGURE 4.3 - Knowledge in Industrialised Building
Systems (IBS)
34%
66%
% GOOD % POOR
“IBS Survey 2005 – Survey on the Malaysian
Architects’ Experience in IBS Construction”.

17. UsagePart 2 :
Promoting Industrialized Building Systems (IBS) – Simplifying
Construction
“IBS Survey 2005 – Survey on the Malaysian
Architects’ Experience in IBS Construction”.
FIGURE 4.5 - Experience in Using IBS Components in
Building Projects
30%
70%
YES NO

18. CharacteristicsPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
5. Systematic Quality Control (ISO 9000 QMS)
2. Labour reduction
3. Modular Coordination - Open building concept
4. Modern design / manufacturing
(ex.CAD/CAM)
1. Industrial production of components (prefab,
precast under controlled environment) or highly
mechanised in-situ processes (slip forms, etc.)

19. 1. Precast Concrete framing, panel,
box systems
TypesPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
PC columns, beams, slabs, 3d-components (balconies,
staircases, toilets, lift chambers, box girders, etc)

20. 2. Steel formworks systems
TypesPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
Tunnel forms, beams and column moulding forms,
permanent steel formworks (metal decks), etc

21. 3. Steel frame systems
TypesPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
Steel beams and columns, portal frames, roof trusses, etc

22. 4. Prefab timber frame systems
TypesPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
Timber frames, roof trusses, etc

23. 5. Block work systems
TypesPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
Interlocking concrete masonry unit, lightweight concrete
blocks, etc

24. 1. Reduction of site labour
2. Minimal wastage
3. Less site materials
4. Cleaner environment
5. Controlled quality
6. Neater and safer sites
7. Faster project completion
8. Lower total construction costs due to the above
BenefitsPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

25. Shorter construction period; if there is consistently large
number of apartments to be constructed.
Time Scale (Months)
Precast System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Production
Foundation Concurrently done ( with 2 week lead time)
Erection
Finishing
Mechanical & Electrical
Infrastructure
Testing & commisioning
Handing Over
Overall completion Period
Conventional System 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Foundation
Construction- superstructure
Finishing
Mechanical & Electrical
Infrastructure
Testing & commisioning
Handing Over
Overall completion Period
18 Month Completion
24 Month Completion
Sumber :Setia Precast
Sdn Bhd

26. 
Labour efficient through mechanisation, reduces 30%
labour
Sumber :Setia Precast
Sdn Bhd

27. IBS – Not A New Concept
Concept of prefabrication started
from the panellised timber houses
(circa, 1624) shipped form England
to the new settlements in America
Ref: Salahuddin, 2001
HistoryPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

28. CIDB’s efforts in promoting IBS
started since 1998
Earlier, concentrated on
Awareness/Promotion/Training
Early EffortsPart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

29. However, 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 (Ref: IBS Survey, 2003)
Main Reason : Relatively cheap and abundant
supply of foreign labour for Malaysian industry
c.f. Labour cost in developed economies such
as Finland - 10 times the rates in Malaysia
(Ref: Gardiner & Theobald, 2002)
UsagePart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

30. 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
UsagePart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction

31. UsagePart 2 :
Promoting Industrialized Building
Systems – Simplifying Construction
IBS components are expensive, so why IBS?
• True. The components cost higher than
conventional, but in-situ construction has
hidden costs that usually lead to higher
expenditure; due to rectifications, wastages, etc
• IBS components currently cost higher because:
Low demand
Low standardisation of components (moulds need to
custom made or adjusted to suit orders)

32. Part 3 :
The Way Forward- The IBS
RoadMap 2003-2010

33. THE WAY FORWARD
IS TO INDUSTRIALISE CONSTRUCTION INDUSTRY
THROUGH COMPONENTS INDUSTRY
BUILT-IN
COMPONENTS
STRUCTURAL
COMPONENTS
RAILING
COMPONENTS
DOOR
COMPONENTS
WINDOW
COMPONENTS
Ref: JKR, 2003

34. Standardisation/ CoordinationPart 3 :
The Way Forward
To facilitate open
industrialization,
coordination is
needed in terms
of :
Dimensions
Tolerance
Joints and details
Technical
compatibility

35. Vendors,
manufacturer
IBS - HOLLISTIC APPROACH
Contractor, assemblers, fabricators
Designers,
(architects, engineers)
Client/Asset
manager
IBS Component
Catalogues
Design Guides
Standardisation/ CoordinationPart 3 :
The Way Forward

36. MS 1064 : 2001 :GUIDE TO MODULAR
COORDINATION IN BUILDINGS
PART 1: General Principles
PART 2: Storey and Room Heights
PART 3: Coordinating Sizes and Preferred Dimensions for Stairs and Stairs
Opening
PART 4: Coordinating Sizes and Preferred Dimensions for Doorsets
PART 5: Coordinating Sizes and Preferred Dimensions for Windowsets
PART 6: Coordinating Sizes and Preferred Dimensions for Rigid Flat Sheet
PART 7: Coordinating Sizes and Preferred Dimensions for Tiles
PART 8: Coordinating Sizes and Preferred Dimensions for Masonry Bricks and
Blocks
PART 9: Coordinating Sizes and Preferred Dimensions for Cabinets
PART 10: Coordinating Sizes and Preferred Dimensions for RC Components
Gazetted oct. 2002Gazetted oct. 2002
Publication Materials

37. Based on MS1064, MC
coordinates the positions,
dimensions of components
and spaces in building designs
Base module :
M = 100mm
Modular Coordination (MC)Part 3 :
The Way Forward
Modularisation
MS 1064

38. New Strategies
New Strategies on IBS & MC needed to promote
industrialisation; Enforcement & Incentives in
addition to Awareness/Promotion/Training
Main target – housing sector (repetitive, high
volume)
Part 3 :
The Way Forward

39. “Closed System”
mass - production
one end product
etc.
Mula-mula:
Projek
Kemudian:
Sistem
Bekalan:
Syarikat tertentu
First a project Then a system
Always third
party supply
Current ScenarioPart 3 :
The Way Forward

40. “Open System”
DESIGN GUIDE
CATALOGUE
etc.
?
?
First a system
Then many
projects
Open supply
Future ScenarioPart 3 :
The Way Forward

41. IBS Roadmap 2003-2010Part 3 :
The Way Forward
5. Marketing/Promotion
2. Materials/Components/Machines
1. Manpower
3. Management/Process/Methods
4. Monetary/Economic/Financial
Formulation of Roadmap based on FIVE main
elements

42. • 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.
Key Elements of RoadmapThe Way Forward
(MANPOWER)

43. • Continue efforts to develop NOSS ( National
Occupational Skill Standards).
• Continue Workers training and certification
programme to include all types of IBS.
• Commence the training programme on mould
making for IBS components.
• Commence the industrial expertise awareness
programme together with IBS manufacture
through on-job training for trainees.
Key Elements of RoadmapThe Way Forward
(MANPOWER)

44. • Commence the site supervisory training and
certification programme which includes
knowledge on IBS
• To start BUMIPUTERA IBS MANUFACTURERS
AND SPECIALISED CONTRACTORS training
and financial aid
Key Elements of RoadmapThe Way Forward
(MANPOWER)

45. • Enforce the 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).
Key Elements of Roadmap
The Way Forward
(MATERIALS)

46. • 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.
Key Elements of Roadmap
The Way Forward
(MANAGEMENT)

47. • 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.
Key Elements of Roadmap
The Way Forward
(MANAGEMENT)

48. • 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.
Key Elements of Roadmap
The Way Forward
(MONETARY)

49. • 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.
Key Elements of Roadmap
The Way Forward
(MONETARY)

50. • 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.
Key Elements of Roadmap
The Way Forward
(MARKETING)

51. 2005 Budget:2005 Budget:
1. Directives:1. Directives:
- Govt building projects- Govt building projects ≥≥ 50% IBS Score50% IBS Score
- 100,000 affordable houses using IBS- 100,000 affordable houses using IBS
2. Incentive:2. Incentive:
- Zero levy for residential projects- Zero levy for residential projects ≥≥ 50% IBS50% IBS
ScoreScore
Budget 2005Part 3 :
The Way Forward

52. IBS ScoringPart 3 :
The Way Forward
• Part 1 – Structural
Element (50%)
• Part 2 – Wall
Element (30%)
• Part 3 – Other
Simplified Solution
(20%)

53. Case StudiesCase StudiesPart 4 :
Case StudiesCase Studies

54. SJK(C) DAMANSARA
PETALING JAYA
SELANGOR DARUL EHSAN
Case StudiesCase StudiesPart 4 :
Sumber : JKR

55. PROJECT DETAILS
Cabinet’s directive - 31Januari 2001
school 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 worksFEB - MAC 2001 Piling works
Case StudyPart 4:

56. Ground level
MAC 2001
MAC 2001
Level 1
•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

57. Roof level
APR - MEI 2001
External works
MAC - APRIL 2001
Level 2
APRIL - MEI 2001
Level 3

58. Back
elevation
Front elevation
Case StudiesCase StudiesPart 4:

59. Case StudiesPart 4 :
 IBS STRUCTURE:
“HOLLOWCORE” SLABS;
PRECAST CONCRETE
COLUMNS & BEAMS
 9,900 m2, 4 FLOORS
 COMPLETION IN 8 MONTHS
CASE STUDY 8 : SCHOOL
SEK. KEB. BRICKFIELDS 1, KUALA LUMPUR

60. PROJECT DETAILS
a compact design to house two schools in
a total site area of 48,220 sq.ft.
•start of project : 6 February 2003
•completion : 17 Sept. 2003
•construction period : 7 1/2 months

61. • 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)
• Architectural features – bright façade,
cascading roofs with large overhangs,
internal pockets of large and small
courtyards
installation of precast column
installation of first floor slab on 02.05.03

62. installation of 3rd floor slab on 28.05.03
installation of precast staircases
fixing of wall panel
completion of external wall on 16.07.03

63. in 2001 – new design alternatives for all categories of government
quarters were initiated
NEW DESIGN FOR GOVERNMENT
QUARTERS
•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

64. Projek Akademi Audit Negara, Nilai, NS
Krtrs kelas F & G – load bearing design, precast wall,
slab, column & beam

65. Projek Akademi Audit Negara, Nilai, NS

66. Projek Balai Polis, Senawang, NS
frame system : cast-in-situ
column & beam, precast infill
wall & slab
Krtrs kelas F
Krtrs kelas G

67. Projek Balai Polis, Senawang, NS

68. Projek Balai Polis, Senawang, NS

69. Case StudiesPart 4 :
 KEDAH STATE GOVERNMENT
 IBS STRUCTURE:
“HOLLOWCORE” SLABS;
PRECAST CONCRETE
COLUMNS & BEAMS
 25,500 m2, 3 FLOORS
 STRUCTURAL
CONSTRUCTION: 4 MONTHS
CASE STUDY 1 : COMMUNITY COMPLEX
DEWAN WAWASAN, KUBANG PASU, KEDAH

70. Case StudiesPart 4 :
 PENANG STATE
GOVERNMENT
 IBS STRUCTURE:
“HOLLOWCORE” SLABS;
PRECAST CONCRETE
COLUMNS & BEAMS
 7,500 m2, 4 FLOORS
 STRUCTURAL
CONSTRUCTION: 2 MONTHS
CASE STUDY 2 : COMMUNITY COMPLEX
DEWAN MILENIUM, KEPALA BATAS, PULAU PINANG

71. Case StudiesPart 4:
 MAJLIS PERBANDARAN
PPINANG
 IBS STRUCTURE:
“HOLLOWCORE” SLABS;
PRECAST CONCRETE
COLUMNS, BEAMS &
BLEACHERS
 6,000 m2, 3 FLOORS
 STRUCTURAL
CONSTRUCTION: 2 MONTHS
CASE STUDY 3: STADIUM
BALIK PULAU INDOOR STADIUM, PULAU PINANG

72. Case StudiesPart 4 :
 IBS STRUCTURE: METAL
FORMWORKS FOR WALLS,
SLABS, BEAMS & COLUMNS
 TWO 26-30 STOREY TOWERS
(APARTMENTS & OFFICES)
 STRUCTURAL
CONSTRUCTION: 6 MONTHS
CASE STUDY 4 : RESIDENTIAL & OFFICE
NORTHAM CITY, PULAU PINANG

73. Case StudiesPart 4:
 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
CASE STUDY 6 : QUARTERS
TEACHERS QUARTERS, ALL OVER MALAYSIA

74. Case StudiesPart 4 :
 CIDB MALAYSIA
 IBS STRUCTURE: PRECAST
CONCRETE SLABS, BEAMS,
COLUMNS & WALLS
 9,600 m2, 6 WORKSHOP
BLOCKS
 STRUCTURAL
CONSTRUCTION: 3 MONTHS
CASE STUDY 7 : TRAINING CENTRE
AKADEMI BINAAN MALAYSIA, SINTOK, KEDAH

75. Case StudiesPart 4 :
 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
CASE STUDY 9 : MEDICAL CENTRE
HOSPITAL SERDANG, SELANGOR

76. Case StudiesPart 4 :
 IBS STRUCTURE: “SOLID” &
“HOLLOWCORE” SLABS;
PRECAST CONCRETE WALLS,
STAIRCASES, GUTTERS,
BEAMS & COLUMNS
 121,000 m2, 4 FLOORS, 2
BASEMENTS
 STRUCTURAL
CONSTRUCTION: 4 MONTHS
CASE STUDY 10 : SHOPPING COMPLEX
IKEA MUTIARA DAMANSARA, SELANGOR

77. Case StudiesPart 4 :
 IBS STRUCTURE: PRECAST
CONCRETE SLABS, WALLS &
STAIRCASES
 756 UNITS, 6 BLOCKS, 8-16
FLOORS
 CONSTRUCTION: 18 MONTHS
CASE STUDY 11 : RESIDENTIAL
APARTMENTS, PRECINCT 9, WP PUTRAJAYA

78. IBS ROADMAP 2003-2010:
towards labour reduction and
better productivity,quality, safety &
environment; reducing total
industry costs
THUS INCREASING THE
INDUSTRY COMPETITIVENESS
Conclusion

79. Thank you