IBS Survey 2003

Survey on the Usage of Industrialised Building Systems (IBS) in Malaysian Construction Industry

Lembaga Pembangunan Industri Pembinaan Malaysia

CONSTRUCTION INDUSTRY DEVELOPMENT BOARD MALAYSIA
Ibu Pejabat CIDB, TIngkat 7, Grand Seasons Avenue, No 72, Jalan Pahang 53000 Kuala Lumpur P.O.Box 12278, 50772, Kuala Lumpur Tel: 603-40448808 Fax: 603-40451808

Simplify It... Use IBS!

http://www.cidb.gov.my

IBS Survey 2003

Survey on the Usage of Industrialised Building Systems (IBS) in Malaysian Construction Industry

IBS Survey 2003

A CIDB Malaysia publication. All rights reserved Library of Congress Cataloging-in-Publishing Data Shaari, Shahrul Nizar Survey on the Usage of Industrialised Building Systems (IBS) in Malaysian Construction Industry ISBN No:1675-6991 Printed in Malaysia

IBS Survey 2003

FOREWORD
Compared to other sectors, the construction industry suffers from low productivity, safety and quality control. Due to the traditional labour-intensive practices, the 3-D Syndrome (Dirty, Difficult & Dangerous) has always been associated with the construction industry. Thus, it threatens the global competitiveness of Malaysian contractors. Because of this, it is important for the local industry players to be ready and to begin sourcing alternatives to the labourbased construction methods. Instead of builders the contractors are to be functioning as assemblers at sites. CIDB strongly supports the use of Industrialised Building Systems (IBS) in order to reduce the dependency on foreign labour and increase productivity, quality and safety in the local construction industry. Since 1998, CIDB has organised programmes with numerous parties in educating the industry on the various benefits of IBS. Five years into the programmes, it is important for CIDB to perform a study on the trend of IBS usage; identify the effectiveness of its current programmes and develop better strategies. This research is also meant to be a reference guide to relevant parties who are interested in effectively producing, marketing and utilising IBS for the Malaysian construction industry. Last but not least, I would like to convey my sincere appreciation to the author and the Construction Technology Unit, Technology Development Division for their effort in producing this research.

Dato Ir. Hamzah Hasan Chief Executive CIDB Malaysia

IBS Survey 2003

PREFACE
This study was undertaken to identify the extent of IBS usage; advantages or weaknesses that affect the users of IBS; acceptance of local contractors to the available IBS in the market; support given by the clients, architects, engineers and government agencies to the contractors; actions to be performed by the government in order to ensure higher and more effective usage of IBS; as well as to identify the existing IBS manufacturers in the market. However, this research stops short of neither making suggestions on government programmes nor business strategies concerning the IBS. Questionnaires were sent to all contractors listed under the G7, G6 and G5 (B and C) CIDB registration list. It can be concluded from the research analysis that the usage of IBS in Malaysia is getting more popular and about one third of the projects completed from 1998 to 2000 used IBS in one form or another. However, its usage in certain areas is still quite low and some parties, especially the clients and government agencies need to be informed on the benefits, as well as the correct applications of the systems. Nevertheless, it can be concluded that most of the respondents were quite positive with increased usage of IBS in the Malaysian construction industry. Shahrul Nizar Shaari Technology Development Division

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IBS Survey 2003

TABLE OF CONTENTS i iv 01 07 15 19 33 38 Foreword List of Charts Section 1 - Introduction Section 2 - Industrialised Building Systems Section 3 - Research Survey Methodology Section 4 - Results and Analyses Section 5 - Conclusion and Limitations References

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IBS Survey 2003

LIST OF CHARTS

CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 CHART 6 CHART 7 CHART 8 CHART 9 CHART 10 CHART 11 CHART 12 CHART 13 CHART 14 CHART 15

- Respondents Based on CIDB Registration Grade - Respondents Based on Designation - Completed Projects 1998 - 2002 - Percentage of Completed Projects Using IBS 1998 - 2002 - Usage of IBS in Projects 1998 - 2002 - Level of IBS Usage 1998 - 2002 - Popular Types of IBS - Common IBS Components - Opinion on Advantages of IBS - Opinion on IBS Knowledge - Opinion on Acceptance Towards Usage of IBS - Opinion on Available IBS in Malaysia - Decision on IBS Usage - Opinion on Compulsory IBS Usage - Suggestions and Comments on IBS Usage

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IBS Survey 2003

SECTION 1

INTRODUCTION

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IBS Survey 2003

Section 1 - Introduction

1.1

T owards Global Competitiveness

In embracing globalisation, it is necessary for the local construction players to be equipped with the relevant technology and experience to successfully market their products and services both locally and globally. Construction Industry Development Board (CIDB) actively promotes the development and usage of new and relevant technology in the process of nurturing construction industry players towards global competitiveness. The Construction Technology Development programmes undertaken by CIDB have been focused on the following items: Industrialised Building System (IBS) Modular Coordination (MC) Standardisation Quality Assurance IT in Construction Research and Development Since 1998, CIDB has been actively promoting the use of IBS in the local construction industry. The contractors are to function as assemblers of components instead of builders. Through the industrialisation of construction, huge amount of work is shifted offsite, resulting to less site labour, materials and wastage; and leaving the construction sites tidier and cleaner. Simplifying and speeding up the processes, IBS disassociates the industry from the 3-Ds or 3-Ks tag : Dirty (Kitanai), Difficult (Kitsui) and Dangerous (Kiken). With IBS, the quality of projects is also easier to control; thus reducing rectification works and lowering the total cost of construction. CIDB strongly supports the use of labour-reducing systems in order to reduce the dependency on foreign labour in the local construction industry. Besides increasing the outflow of Ringgit to foreign economies, dependency on foreign labour brings about
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IBS Survey 2003

several negative impacts to the nation within the social and cultural context. Programmes have been organised with numerous parties in educating the industry on the various benefits of IBS. In enhancing the global competitiveness of Malaysian contractors, CIDB has deployed large funds for researches, standards development as well as various training and promotion programmes. CIDB has been sponsoring numerous Research and Development programmes to develop innovative IBS applications. Workers are not only being trained in the basics of conventional construction methods, but also in the installation of IBS components and IBS site management. Five years into this programme, we have realised that it is important for CIDB to perform a study on the trend of IBS usage in the local construction industry.This will test the effectiveness of its current programmes and lay the foundation to formulate new strategies.The Construction Technology Unit of CIDBs Technology Development Division conducted a survey research on the usage of IBS in Malaysian construction industry.

1.2

Objectives of the Survey Research

This study IBS Survey 2003 Survey Research on the Usage of Industrialised Building Systems in the Local Construction Industry was undertaken to identify: The extent of IBS usage in the Malaysian construction industry; Advantages or weaknesses that affect the users of IBS; Acceptance of local contractors to the available IBS in the market;

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IBS Survey 2003

Section 1 - Introduction

Support given by the clients, architects, engineers and government agencies to the contractors; Suggestions and comments on usage of IBS in the Malaysian construction industry; Existing IBS manufacturers in Malaysia. IBS Survey 2003 is also meant to be a reference for relevant parties who are interested in effectively producing, promoting and utilising IBS for local construction projects. However, this research does not cover any business strategy or future programmes by the government in promoting the usage of IBS in Malaysia.

1.3

Scope of Research
In general, this research was done in three stages, namely: Literary study on IBS Survey on the extent of IBS usage as well as the users perceptions and suggestions Analysis of the returned forms and conclusions.

Making references to relevant books, journals and other sources, as well as conducting literature study on IBS and its applications were performed in the first stage of the research. The second stage involved a research survey using the Questionnaire Survey Method. The respondents identified for the survey were those involved in the usage of IBS the contractors. A total of 5172 sets of questionnaires were sent to all contractors listed under

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Section 1 - Introduction

IBS Survey 2003

the G7, G6 and G5 (B and CE) CIDB registration list.The third and final stage of the study was the analysis of the questionnaire forms returned by the respondents. The final stage ends with the writing of findings and conclusions.

1.4

Structure of Report

This report is divided into five Sections and each can be generally summarised as follows: Section 1 introduces the readers to the research report and briefly explains about CIDBs efforts in promoting usage of IBS and other relevant technologies towards global competitiveness. It also consists of the objectives and the scope of work for the study and ends with the summary of the research report. Section 2 describes IBS in general and covers the definition, types and applications of IBS in the construction industry. Section 3 explains the research survey methodology for the study and includes the method of data collection and questionnaire structure. Section 4 consists of the interpretation and analysis of the results obtained from the survey research. Section 5 states the conclusion and limitations of the study.

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IBS Survey 2003

SECTION 2

INDUSTRIALISED BUILDINGSYSTEMS

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IBS Survey 2003

Section 2 - Industrialised Building Systems

2.1

Definition

It is interesting to note that the term Industrialised Building Systems (IBS) is often misinterpreted as systems limited only for the construction of buildings. In fact, IBS covers all types of structures as the word building actually relates to constructing. IBS may be defined as construction systems in which components are manufactured in a factory, on or off site, positioned and assembled into a structure with minimal additional site works (1). The six characteristics of IBS are: Industrial production of components though prefabrication; or highly mechanised in-situ processes i.e. slip-forms, posttensioning, tunnel shutters. Reduced labour during prefabrication of components and site works. Modern design and manufacturing methods i.e. involvement of Computer Aided Design (CAD) and Computer Aided Manufacturing (CAM). Systematic Quality Control i.e. ISO 9000 principles. Open Building Concept i.e. permitting hybrid applications, adaptable to standardisation and Modular Coordination (MC). Systems to be accepted as part of IBS need to possess all of the above, as all of the five characteristics are equally important to ensure the achievement of the claimed benefits.

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Section 2 - Industrialised Building Systems

IBS Survey 2003

2.2

Types of IBS

Based on structural aspects, IBS can be divided into five major types (2): Type 1: Pre-cast Concrete Framing, Panel and Box Systems The most common group of IBS products is the pre-cast concrete elements pre-cast concrete columns, beams, slabs, walls, 3-D components (e.g. balconies, staircases, toilets, lift chambers, refuse chambers), lightweight pre-cast concrete, as well as permanent concrete formworks. Type 2:Steel Formwork Systems Considered as one of the low-level or the least prefabricated IBS, as they generally involve site casting and are therefore subject to structural quality control, the products offer high quality finishes, and fast construction with less site labour and material requirement.These include - tunnel forms, tilt-up systems, beams and columns moulding forms, and permanent steel formworks (metal decks). Type 3:Steel Framing Systems Commonly used with pre-cast concrete slabs, steels columns and beams, steel framing systems have always been the popular choice and used extensively in the fast-track construction of skyscrapers. Recent development in this type of IBS includes the increased usage of light steel trusses consisting of cost-effective profiled cold-formed channels and steel portal frame systems as alternatives to the heavier traditional hot-rolled sections.

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Section 2 - Industrialised Building Systems

Type 4:PrefabricatedTimber Framing Systems Among the products listed in this category are timber building frames and timber roof trusses. While the latter are more popular, timber building frame systems also have its own niche market; offering interesting designs from simple dwelling units to buildings requiring high aesthetical values such as chalets for resorts. Type 5: Blockwork Systems The construction method of using conventional bricks has been revolutionised by the development and usage of interlocking concrete masonry units (CMU) and lightweight concrete blocks.The tedious and time-consuming traditional brick-laying tasks are greatly simplified by the usage of these effective alternative solutions.

2.3

History

The concept of IBS is not new and can be traced back to as early as 1624 when panellised timber houses were shipped from England to the new settlements in North America (3).The Industrial Revolution of the 1700s provided the construction industry with technological boost. The construction of the first cast iron bridge across the Severn Gorge, at a place now known as Ironbridge in Shropshire, England, revolutionised the way structures were built. Then, numerous magnificent iron-based structures were constructed; including the modular-dimensioned Crystal Palace in Hyde Park, London for the 1851 Great Exhibition and the Eiffel Tower for the Paris World Expo and French Revolution Centenary Celebration in 1889.The development of steel and other pre-engineered materials promoted the race to build tall structures, particularly in the United States where steel frames are often combined with pre-cast panels in building skyscrapers.
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Section 2 - Industrialised Building Systems

IBS Survey 2003

While steel structures of road and railway bridges were common in preindependence Malaya, the use of pre-cast concrete in the local construction industry arrived much later. In 1966, the Malaysian government launched two pilot projects the Pekeliling Pekeliling Flats, Kuala Lumpur Flats in Kuala Lumpur and the Rifle Range Road Flats in Penang; both using precast concrete elements to build these high rise low cost flats. Following these pilot projects, PKNS acquired pre-cast concrete technology from Praton Haus International, Germany and built numerous housing projects ranging from low cost National Aquatic Stadium, Bukit Jalil houses to high cost bungalows from 1981-1993 (4).The success of pre-cast, steel and hybrid construction contributed to the rapid creation of numerous beautiful and quality structures; particularly during the 1995-1998 period. These include the construction of the Bukit Jalil Sports Complex and Games Village, the Petronas Twin Towers and the LRT lines and tunnels. IBSs benefits are inherent in the beautiful structures
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IBS Survey 2003

Section 2 - Industrialised Building Systems

of the Putrajaya precincts and in the projects to improve Kuala Lumpurs infrastructure. Others include the construction of elevated highways using pre-cast concrete box girders as well as the monorail lines utilising arched pre-cast concrete beams. However, even after nearly four decades of introduction, it appears that the usage of IBS in Malaysia is still low compared to that of other developed countries such as Japan, UK,Australia and US. It is a loss for the local industry players as IBS offers solutions to the issues previously identified (5), which would definitely exert a major impact on the industry productivity, quality, health and safety, and the environment.

Petronas Twin Tower, Kuala Lumpur

Terrace Houses, Putrajaya

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Section 2 - Industrialised Building Systems

IBS Survey 2003

Samples of IBS Applications

LRT Stations, Kuala Lumpur

Telekom Building, Bangsar

Kuala Lumpur Tower

IBS Survey 2003

Section 2 - Industrialised Building Systems

Apartments, Putrajaya

KL Sentral

IBS Survey 2003

SECTION 3

RESEARCH SURVEY METHODOLOGY

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IBS Survey 2003

Section 3 - Research Survey Methodology

3.1

Method of Data Collection

In this research, the method used for data collection was the Questionnaire Survey. A literature research was performed to guide the formulation of the questionnaire.

3.2

The Questionnaire

The questionnaire forms were designed to be simple and which would require minimal filling-in time. It consisted of five parts a company profile, a survey on the usage of IBS elements in their construction projects, opinion survey questions, a list of IBS manufacturers; and lastly suggestions and comments on the IBS usage. Respondents were requested to attach their business cards to the questionnaire forms. The information gathered was as follows: Part 1 - Company Profile Position of respondent in the company. Company address and contact number for reference. CIDB Registration grade of the company. Part 2 - Survey on Completed Projects Number of completed projects by the company concerned. Number of completed projects utilising IBS. Popular IBS components used. Part 3 - Opinion Survey The claimed benefits of using IBS.

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Section 3 - Research Survey Methodology

IBS Survey 2003

IBS knowledge of architects, engineers, clients and government (approving) authorities. Acceptance towards IBS usage by the architects, engineers, clients and government (approving) authorities. The available IBS in Malaysia. Using IBS in future construction projects. Making compulsory IBS usage in construction. Part 4 - List of IBS manufacturers Set-up a database on IBS manufacturers and suppliers. Identify the popular types of IBS. Part 5 - Comments and Suggestions 4 Respondents comments on the usage of IBS in construction projects. 4 Suggestions for enhancement.

3.2

Sampling

IBS Survey 2003 was a two-month long (January to February 2003) research programme involving data collection through questionnaire forms that were sent out to 5172 contractors registered with CIDB under the G7, G6 and G5 (B and CE) categories, as of the November 2002 list.The rationale for this was because the scope of the research covered only the completed projects by the main contractors in order to avoid data overlapping; and the G7, G6 and G5 contractors were considered most likely to be getting the bulk of projects.Their responses were then analysed and discussed in the following sections.

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IBS Survey 2003

SECTION 4

RESULTS AND ANALYSES

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IBS Survey 2003

Section 4 - Results and Analyses

4.1

Data Collection

The respondents were given the option of returning the questionnaire forms by mail or fax. A total of 175 companies out of 5172 returned the questionnaires to CIDB. Though only 3.4% of the companies replied, this low percentage had been expected for a mailed and questionnaire-based survey research.

4.2

Analysis of Data
4.2.1 Respondents

Of the 175 completed forms, 10 uncompleted questionnaires (5.7%) were rejected and the analysis was based on the remaining 165 questionnaires (Chart 1). Of these, 60% was G7-registered contractors, 8% was G6, 16% was G5 and 15% of the respondents did not state the grades. Unexpectedly, one was a G4-listed company completed the questionnaire, most likely due to recent downgrading of registration grade.
CHART 1: THE RESPONDENTS
(BASED ON CIDB REGISTRATION GRADE)
15%

1%
16%

60%

8%

G7

G6

G5

G4

NO T STATED

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Section 4 - Results and Analyses

IBS Survey 2003

Most (50%) of the respondents came from the top management level, which is good for an opinion survey analysis, as the respondents are more likely to portray the actual company direction (Chart 2). 18% of the respondents did not state their post.
CHART 2: THE RESPONDENTS
(BASED ON DESIGNATION)
1 8%
9%

50%

1 8%
5%

DIRECTOR, CEO, MD

GM
OTHERS

MANAGER

NOT STATED

4.2.2 Popular IBS Projects The 165 respondents have completed a total of 1310 projects (as main contractors) from the year 1998-2002. On average, each of the contractors have completed 8 projects in the 1998-2002 period.As highlighted in Chart 3, the construction of buildings formed the bulk of the projects (72.5%).
CHART 3: COMPLETED PROJECTS 1998-2002
18.3%
0.6%

5.7%

0.2%
2.6%
BRIDGES

72.5%
BUILDINGS
RETA INING STRUCTURES MA RINE STRUCTURES

TUNNELS
OTHERS CONSTRUCTION PROJECTS

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IBS Survey 2003

Section 4 - Results and Analyses

CHART 4: PERCENTAGE OF COMPLETED PROJECTS USING IBS (1998-2002)

45% 45% 40% 40% 35% 35% 30% 30% 25% 25% 20% 20% 15% 10% 10% 5% 5% 0% 0% 42% 30% 21% 24% 34% 32%

CHART 5: USAGE OF IBS IN PROJECTS (1998-2002)

100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40% 40% 30% 30% 20% 20% 10% 10% 0% 0%
1 00% 80% 75% 75% 50% 40% 39% 34% 29% 27% 86% 1 1 1 1 00% 00% 00% 00%

22% 1 3% 0%0%0% 0%0%0%0%0%

9% 4% 0%0%0%

1998

1999

2000

2001

2002

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OTHERS CONSTRUCTION PROJECTS

RETAINING STRUCTURES

MARINE STRUCTURES

BUILDINGS

TUNNELS

BRIDGES

5-YEAR AVERAGE

1998

1999

2000

2001

2002

Section 4 - Results and Analyses

IBS Survey 2003

Road, landscaping and earthwork projects were grouped under Other Construction Projects as IBS is not applicable. Drainage was also included in the group, as most of the respondents had specified road and drainage projects. Furthermore, most drainage projects are highly IBS-ed. As presented in Chart 4, completed projects using at least one IBS component (frames, slabs, roof trusses etc.) increased steadily from 21% in 1998 to 42% in 2002. For the 5-year average, 31.6% of the completed projects had utilised IBS. Chart 5 illustrates that the IBS usage in the construction of bridges and tunnels during the period of study (1998-2002) was very high (83.2% and 90% respectively) while only 33.8% of buildings utilised IBS. In comparison, IBS usage was very low in the construction of retaining structures and marine structures. In fact, marine structures recorded zero usage for the five-year period. The usage of IBS in the Other Construction Projects was very low as was expected. The recorded IBS usage in that category was from the drainage projects. As shown in Chart 6 (overleaf), companies with zero usage of IBS in construction projects were recorded to be steadily decreasing from 1998 (74%) to 2002 (48%). Clearly, more companies are beginning to accept and use IBS in their construction projects. The number of companies that utilised IBS in 81%-100% of their projects also recorded a steady increase.

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Section 4 - Results and Analyses

CHART 6: LEVEL OF IBS USAGE (1998-2002)

100% 100% 90% 90% 80% 80% 70% 70% 60% 60% 50% 50% 40% 40% 30% 30% 20% 20% 10% 10% 0% 0%
74%

69%

64%

61% 48% 26% 4% 6% 3% 9% 9% 30%

63%

16% 4% 3% 3% 6% 8%

15% 1% 7% 6%

21% 2%

22% 3% 6% 6% 2%

ZERO USAGE (0%) LOWUSAGE (1-40%) MEDIUM USAGE (41-60%) HIGH USAGE (61-80%) VERYHIGH USAGE (81-100%)

4.2.3 Popular IBSTypes and Structure Components The respondents named a total of 87 IBS manufacturers. As stated in Chart 7, the most (40%) are Type 3 manufacturers (Steel beams and columns as well as portal frames and cold-rolled roof trusses). This is followed by Type 1 manufacturers whose products (25%) consists of the pre-cast concrete framing, panel and box systems. Added under Others in addition to the five common

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5-YEAR AVERAGE

1998

1999

2000

2001

2002

Section 4 - Results and Analyses

IBS Survey 2003

CHART 7: POPULAR TYPES OF IBS

5%
14%

1%

25%

15%

40%

Type 1: P recast C oncrete

Type 2: Steel Form work

Type 3: Steel Fram es

Type 4: Tim Fram ber es

Type 5: Blockworks

Others

types of IBS were the fibreglass formworks. The most popularly used IBS structure component in the 19982002 period, as highlighted in Chart 8 (overleaf), was the roof trusses (55%) due to positive market acceptance to the usage of prefabricated steel and timber roof systems.As for columns, beams, walls and slabs, IBS usage was in the 15%-20% region, while IBS usage in other categories was recorded to be very low.

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IBS Survey 2003

Section 4 - Results and Analyses

CHART 8: COMMON IBS COMPONENTS

100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 6% 0%
21% 19% 16% 15% 16% 9% 4%
Beams Ground Slabs Columns

96% 94%

96%

98% 91%

99% 99% 99% 99%

85% 84% 84% 81% 79%

55% 45%

4%
Slabs Portal Frames Staircases Non-load Bearing Walls Load Bearing Walls

2%
Roof Trusses Architectural Facades

1% 1% 1% 1%
Bleachers Box Girders Parapets Tunnels

Ground Beams

Have Used

Haven't Used

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Section 4 - Results and Analyses

IBS Survey 2003

CHART 9: OPINION ON ADVANTAGES OF IBS SYSTEMS

100% 90% 80% 60% 50% 40% 30% 20% 10% 0%
Open / flexible system Easy installation Cleaner, neater and safe construction sites Labour reduction Fast completion Enhancing quality of finished products Lowering total construction cost 7% 2% 8% 6% 92% 84% 77% 59%

90%

86%

4.2.4 Opinion Survey 70%

49% 41% 28% 13% 7% 2% 12% 11% 10%

Chart

8% 8%

Agree

Don't Agree

Not Stated

As stated in Chart 9, most of the respondents agreed that IBS promoted cleaner sites, less labour requirement, faster completion and the enhancement of quality finished products. However, the majority of the respondents did not agree that the systems would lower total construction costs.
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Section 4 - Results and Analyses

CHART 10: OPINION ON IBS KNOWLEDGE

100% 80% 60% 40% 20% 0%
68% 47% 41% 13% 22% 10% 62% 27% 11%

47% 39% 13%

Good

Poor

Not Stated

CHAR T 11: OPINION ON ACCEPTANCE TOW AR DS USA GE O F IBS

100% 80% 60% 40% 20% 0%
6 9% 52 % 36 % 12 % 4 6% 4% 4 21 % 10 % 1 0%

56 % 32 % 12%

Architec ts

Engineers

C lients Governm ent (Private and (Approving) Public ) Authorities

Good

Poor

Not Stated

28

Government (Approving) Authorities

Clients (Private and Public)

Architects

Engineers

Section 4 - Results and Analyses

IBS Survey 2003

Most of the respondents felt that the (consulting) engineers (68%) and architects (47%) had good knowledge of IBS while the government (approving) agencies, private and public clients had poor IBS knowledge. (Chart 10) Quite a number stated No Comment, which could reflect on their unfamiliarity of IBS. Chart 9 shows that the majority of the engineers (69%) and architects (52%) had good acceptance to IBS usage (Chart 11). It was also found that the majority of the clients and the government agencies involved had been positively accepting IBS usage. As quite a number of the respondents had stated No Comment to the question, the results and actual scenario might not be so accurate. With reference to Chart 12, the majority or 41% of the respondents felt that the available IBS systems in Malaysia were good while about 32% thought the opposite.The rest, (27%) were those in the grey area. The majority of the respondents (54%) planned to use IBS in their next project while 41% were unsure. Only a very small fraction (5%) of the respondents had already decided not to use IBS (Chart 13 overleaf).

CHART 12: OPINION ON AVAILABLE IBS IN MALAYSIA

27% 41%

32%

GOOD

POOR

NOT SURE

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Section 4 - Results and Analyses

CHART 13: DECISION ON IBS USAGE (TO USE IBS IN NEXT CONSTRUCTION PROJECT)

41%

54%
5%

YES

NO

NOT SURE

Nevertheless, in Chart 14, more than half of the respondents (61%) supported the idea of imposing a certain percentage of compulsory usage of IBS. However, out of the 165 respondents, only a small number (8%) preferred compulsory usage. About a fifth (19%) totally opposed to the idea of making IBS usage compulsory.
CHART 14: OPINION ON COMPULSORY IBS USAGE 8% 19%
12%

61%
YES, TOTALLY IBS

YES, BUT SET A CERTAIN PERCENTAGE

NOT SURE
NO

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Section 4 - Results and Analyses

IBS Survey 2003

4.2.5 Suggestions from Respondents Chart 15 (overleaf) compiled the suggestions and comments given by the respondents on the usage of IBS in the Malaysian construction industry. The majority of the respondents (37%) felt that more IBS awareness and education programmes through courses and seminars were needed. 14% insisted on incentives to be given by the government to spur the growth of IBS usage in Malaysia.The respondents also wanted workers training programme to include IBS skills (9%), standardisation of components established (9%) and making architects design according to MC (8%). Only 1% of the respondents stated that they preferred conventional methods.

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Section 4 - Results and Analyses

CHART 15: SUGGESTIONS AND COMMENTS ON IBS USAGE

8% 9% 9% 14% 1% 9% 37% 4% 8% 5% 4% 1%

Education Awareness on IBS Through Courses and Seminars Incentives from Govt to Lower Costs of Using IBS Train Workers in IBS Knowledge Standardize Sizes and Shapes of Components Make Architects Design In Accordance to Modular Coordinatoin (MC) Proof of Cost and Time Savings Promote Formation of Other Suppliers to Avoid Monopoly Promote Formation of Other Suppliers To Avoid Monopoly Promote Designers To Design in IBS (Not Conversion) Make IBS Compulsory Form R & D Centre Prefer In-situ

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IBS Survey 2003

SECTION 5

CONCLUSION AND LIMIT TIONS A

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IBS Survey 2003

Section 5 - Conclusion & Limitations

5.1 Conclusion The research involved literature study, survey research and analysis of the survey. A summary of the research findings is as follows: On average, each company completed 8 projects between 1998-2002. The majority (72.5%) of the projects was the construction of buildings. However, IBS usage in building construction was low (33.8%). In general, usage of IBS is not uncommon in Malaysia and is increasing each year. Completed projects using IBS elements in one form or another increased steadily from 21% in 1998 to 42% in 2002. 31.6% of all completed projects during 19982002 used IBS. The construction of bridges (83.2%) and tunnels (90%) greatly utilised IBS. Companies with zero IBS-utilised projects were decreasing from year to year (74% in 1998, 64% in 2000, and 48% in 2002). The greatest number of IBS manufacturers is of Type 3 (Steel Framing Systems). This constitutes 40% of all IBS producers. Next is Type 1 (Pre-cast Concrete) producers (25% of the total number of 87 producers). The most popular IBS component is the roof trusses and 55% of the respondents have used the systems. 15% have used IBS in frames, slabs and walls. Most disagree on the ability of IBS to lower total construction costs. However, the majority agreed that IBS offers cleaner and neater sites (90%), easy installation (86%),
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Section 5 - Conclusion & Limitations

IBS Survey 2003

flexibility (59%), labour reduction (92%), fast completion (84%) and the enhancement of quality finished products (77%). Most of the respondents felt that the architects and engineers have good knowledge in IBS (47% and 68% respectively). However, many feel that private and public clients (62%) and the government approving authorities (47%) have poor IBS knowledge. The majority of the respondents feel that all parties (architects, engineers, clients (private and public) and the government approving authorities) accepted the use of IBS in construction (52%, 69%, 46% and 56% respectively). The majority of the respondents (41%) feel that the available IBS in Malaysia are good. Most of the respondents (54%) would like to use IBS in their next construction project. 61% (majority) prefer IBS to be made compulsory but to set certain percentage of usage. The majority (37%) of the given suggestions is a request for more IBS awareness and education programmes to be conducted by CIDB. Note: Some of the figures stated as the majority are actually less than 50%. This is because of a high percentage of Not Stated/No Comment choices. It can be concluded generally that the usage of IBS in Malaysia is getting more popular and about one third of the projects completed from 1998 to 2002 used IBS in one form or another.
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IBS Survey 2003

Section 5 - Conclusion & Limitations

55% of the local contractors have used prefabricated roof trusses while 15% have used a type of IBS in frames, walls and slabs. However its usage in certain areas is still quite low and some parties need to be informed of the benefits as well as the correct applications of the systems. Nevertheless, most of the respondents were quite positive with the increased usage of IBS in the Malaysian construction industry. 5.2 Limitations As research goes, this study has its own limitations that affected the results of the findings: The respondents The 165 respondents only represent 4% of the targeted sample. The registration list may not have been updated correctly in terms of address, etc. Not Sure inputs The large percentage of Not Sure and Not Stated inputs affected the results and actual scenario. Actual IBS usage A project considered as an IBS Project might in fact only used a small fraction of IBS elements. Actual number of IBS manufacturers The actual number depends on the respondents understanding of the IBS. Some may not produce IBS products.

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IBS Survey 2003

While further detailed researches are proposed, the information gained is considered sufficient for this maiden research of IBS usage in Malaysia. As stated earlier, this research stops short of neither making suggestions on future government programmes nor strategies in increasing the usage of IBS in Malaysia nor suggests any business strategies concerning the IBS.

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REFERENCES (1) (2) CIDB Malaysia, Manual for Assessment of Industrialised Building Systems, CIDB, Kuala Lumpur, 2001. Shaari, Shahrul Nizar and Ismail, Elias, Promoting the Usage of Industrialised Building Systems (IBS) and Modular Coordination (MC) in Malaysian Construction Industry in Buletin Ingeniur, Board Engineers of Malaysia (BEM), Kuala Lumpur, March 2003. Sumadi, Salihuddin Radin, et al, Promotion Strategies and Future Research & Development, National Seminar on Industrialised Building System, CIDB, Kuala Lumpur, 17 September 2001. Hashim, Mohd. Suffian, The Industrialised Construction System Pengalaman (The Experience of) PKNS Engineering & Construction Berhad (PECB) in Colloquium on Industrialised Construction System, CIDB, 9 April 1998. CIDB Malaysia & APEC Technology Foresight Centre, Bangkok, Malaysian Construction Industry: Technology Foresight Report, Proceedings of the CIDB Workshop on Technology Foresight, CIDB, Kuala Lumpur, 2122 March 2000.

(3)

(4)

(5)

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ACKNOWLEDGEMENTS
This research was conducted by Shahrul Nizar Shaari with contribution from Ir. Elias Ismail, Sazali Che Amat, Anisa Zainal Abidin, Che Zakaria Aziz, Syahrul Nizam Aziz & Nor Fazliyana Rauzan of the Construction Technology Unit, Technology Development Division CIDB.