1.

0 INTRODUCTION

Industrialized building system (IBS) nowadays is a part of innovation in construction which also
takes a role in project life cycle. IBS definitions are different in context according to one’s
experience and understanding. Some may define it as a process, system or techniques and
methods in construction industry. Countries to countries defined it variously based on their
definition acceptation either based on the ontology or characteristics. Dietz (1971), Dickerman
(1973), Junid (1986), Warzawski (1999) and such authors defined it as a process while Parid
(1997), Esa and Nuruddin (1998), Trikha (1999) and other authors take the IBS as a techniques
(Abdullah et al., 2009).

In Malaysia, by the Construction Industry Development Board (CIDB), IBS is defined as a

technique of construction where before the components such as beam, column, wall or slab are
construct into a building, those components are manufactured in a controlled environment on-site
or off-site. Once completed components transported to site according to structure requirements to
minimize additional on-site works (Kamar, 2010). It has been used for a long time in order to
substitute traditional practices. It is an improvement in construction industry in modern method
of construction.

Besides, IBS is some kind of building modular structures to provide in order to improve
construction process which gives benefits to the industry. Advantages of IBS include the term of
cost, time, quality and safety. With traditional techniques, numerous materials are used to
construct structures components. Those material wastes can be minimized by replacing the
traditional process into IBS through the quality control. Components are ready made by the
manufacturer thus it only will be transferred to the site devoid of site works. On the other hand to
save the cost, necessity for on-site workers appreciably reducing the needs of the cost for labour
salary and benefits comes to the contractors. In terms of quality, IBS concept results in high
quality-controlled product by standard operating procedure (Kementerian Kewangan Malaysia,
2008).

According to Roadmap IBS 2003-2010, increasing quality of product is one of the objectives of
the system. For this reason, of course IBS increasing better quality control. Skilled and
knowledgeable workers improve efficiency and reducing errors nevertheless increasing quality

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of the product. Time factor is the part of why IBS is come out. Due to more on off-site
preparation, the points in completing the projects are faster with an efficient installation. In
addition, by off-site production IBS also can be done 24 hours without affected by the weather.
IBS advantages in terms of safety obviously in minimal requirement of works on site and
systematic work at the manufacturer factory promote safer working environment. Material
delivery from off-site production results on cleaner sites and reduce construction materials and
waste. IBS gives the ability for industry and country to improve, up to date and go forward with
advance in industrialization.

1.1 Method of Construction

According to Badir-Razali (1998), there are four categories of construction method in Malaysia,
i.e. conventional method, cast-in situ, composite method and fully prefabricated system. These
building systems are represents by their respective construction method, characterised by the
construction technology, functional and geometrical configuration. Generally cast-in situ,
composite method and fully prefabricated are classified as non conventional methods and all
types of IBS are categorized under these three methods.

1.1.1 Conventional Construction Method

In conventional building method, the building is prefabricated on-site through the process of
timber formwork installation, steel reinforcement and cast in-situ; mostly built of reinforce
concrete frames. It is also expensive due to usage of labor, materials, transportation etc.

1.1.2 Cast In-Situ Method

Badir (1998) pointed out that cast in-situ method is suitable to be used at country which has
limited skill labor because there is less or no heavy machinery or high technology involved.
Besides, this system is applicable to almost all types of building too. Generally, cast in-situ
method is applied to reduce the traditional site-based trades such as traditional brickwork or
timber form work. Therefore a well planned in-situ work for sure can maximize the work’s
productivity, speed, accuracy etc.

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1.1.3 Prefabricated System

All prefabricated elements are standardised during prefabrication process in the factory. It
involves the assembly of precast elements such as floor slabs, in-filled walls, bathrooms,
staircases, etc. into place for incorporation into the main units, columns and beams. Therefore it
has reduced the amount of site labor as well as increase the productivity of the industry.

1.1.4 Composite Building

Composite construction method, also known as partially pre-fabricated system, is used to

improve quality, reduce cost, and shorten the construction time. This concept is derived from the
composite nature of full industrialization in order to describe a manufacturing or production
strategy that selectively uses some industrializing aspects.

1.2 Types of IBS

Apart from that, the structural aspect of IBS is divided into five major types, stated as follows
(Azam J. et al., 2009):

i. Pre-cast concrete framing, panel and box system: Pre-cast beams, columns, slabs, 3-D
components e.g. lift and staircases etc.
In Malaysia, pre-cast components are the most common prefabricated elements.
Normally, pre-cast concrete is manufactured and cured in a plant and transported to site
for installation later on.

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 Figure 1: Pre-Cast Concrete Wall

ii. Steel formwork system: beams and columns moulding forms, permanent steel
formwork e.g. metal decks etc.
Steel formwork is generally prefabricated in factory then install on site later. The
installation process is easy by just using simple bracing systems.

Figure 2: Steel formwork system

iii. Steel frame system: steel beams and columns, portal frames, roof trusses etc.
The elements of steel framing systems are usually fabricated by cutting, drilling, shot
blasting, welding and painting before sent to the construction site.

Figure 3: steel roof trusses

iv. Prefabricate timber frame system: timber frame, roof trusses etc.
The prefabricated timber framing system is normally used in conventional roof truss and
timber frames. The timber is prefabricated to join all the truss members. Somehow, all of
the members must be treated with anti pest chemical before install on site.

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 Figure 4: double storey house – prefabricated timber frame system

v. Blockwork system: interlocking concrete masonry units, lightweight concrete blocks

etc.
Blockwork systems elements are fabricated and cured in factory and are usually used as
bricks in structures or interlocking concrete block pavement.

Figure 5: wall construction – lightweight concrete blocks

(Pictures Source: http://www.scribd.com/doc/21794505/Ibs-Complete)

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2.0 Discuss on Current Scenario of Malaysian Construction Industry in terms of :
2.1.1 Labour

Construction industry in Malaysia is still using conventional techniques which mean that using
more labour efforts. For the reason that local government workers are not interested in this type
of job because of their dirty, dangerous, and difficult perception, greater percentage of foreign
workers are hired in construction industry. The role of foreign workers in Malaysia construction
industry to balance construction cost is undeniable as the salary for their job is credible.
However, by depending on foreign workers will results in an outflow currency and disturbing the
social balance and economy. CIDB has conducted a survey on the status of local government and
foreign workers in Malaysia and how to overcome such problems. The study is cover only on-
site workers including skilled, semi skilled and unskilled workers.

60 Malaysia
50 Other Countries (Nepal,
Myanmar, India,
40 Vietnam and Sri Lanka)
30 Bangladesh
20 Indonesia

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0
Foreign Workers Local Workers

Figure 6: Foreign Workers vs. Local Workers

Among the total workers in construction industry on site, foreign workers accounted for 52%
while the remaining 48% were domestic workers (CREAM & CIDB, 2010). From the 52% of
foreign workers 59% of it are Indonesian, 13% are from Bangladesh, and other 28% are from
others countries such as Nepal, Myanmar, India, Vietnam and Sri Lanka. Private sectors hire
more foreign workers compared to the government due to IBS used as construction techniques.

Selangor, Sabah, Kuala Lumpur, Johor, Malacca, Penang, Pahang, Perak and Kedah have higher
percentage of foreign than the local workers at construction sites. Meanwhile, Sarawak,
Kelantan, Terengganu and shows the percentage of local recruitment.

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By introducing IBS in Malaysia construction industry gives local workers towards better image.
The Technology of IBS requires more skills and paid with credible salary. This encourages
domestic workers to recruit into this industry in order to contribute Malaysia into high-income
country. Foreign workers are still relevant to current construction situation but the numbers must
be reduced to minimum rate. Malaysia construction industry also should focus on skilled labour
in manufacturing to continue contributing towards the country. Accreditation for locals and
foreigners should be implemented to ensure the quality of work is achieving the standard.

2.1.2 Materials

Current scenario stressed in Malaysia Construction Industry is the environment issues. This issue
is related to materials of the construction either on site or the off site construction. According to
Ping, Omran and Pakir, 2009, material waste has been provoking an environment issue in
Malaysia construction industry. Excessive waste actually can take place at every stage of
construction activities. Ping, Omran and Pakir pointed out that the contractors do not concern
and lack of considerations with this issue and the waste level has become greater. It is still
emphasized and considered as a problem in country construction industry on 2010 and there is
still an issue of minimizing construction waste until now. Infrastructure projects, commercial
buildings and housing constructions are in demand currently and construction material waste
increasing in large numbers. It is undeniable that the waste of materials could not be avoided and
abolished into zero percent but it can be reduced to lower amount of wastes.

As a solution, Malaysia construction industry using prefabrication and Industrialized Building

System (IBS) where this system strongly reducing the huge amount of material wasted. In
American Journal of Environmental Science, different categories of materials and the quantity of
wasted material have been studied. Major categories are including soil and sand, bricks and
blocks, concrete and aggregates, metal and wood (Begum, 2010). There are some other materials
too. The results obviously show that by using fully prefabricated construction, there are large
different of numbers in materials wastage.

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 (Picture source: www.scipub.org/fulltext/ajes/ajes64383-388.pdf - United States)

Components and type of IBS widely used in constructions which in point of fact it reduce the
materials waste are such as precast concrete, load bearing block, sandwich panel and steel frame.
From American Journal of Environmental Sciences 6-2010 from the CIDB 2003a; IBS DIGEST
2007 types of IBS divided into five (Begum, 2010):

o Precast Concrete Framing, Panel and Box system :

Pre-cast Columns, Beams, Slabs, 3-D components (balconies, staircases, toilets, lift
chambers) and permanents concrete formworks.

Figure 7: Precast beam and column

connected

Picture Source:
http://www.pmbuildconsultants.com/

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 Figure 8: Installation of precast beam
and column

Picture Source:
http://ibsmodular.blogspot.com/

Figure 9: Precast concrete frame

Picture Source:
http://ibsmodular.blogspot.com/

o Steel formwork system :

Tunnel form, Expanded Polystyrene (EPS) forms, Beams and Columns moldings
forms, and permanent steel formworks.
o Steel Framing System:
Steel Beams and Columns, portal frames and Roof trusses.
o Prefabricated timber framing system:
Timber frames and roof trusses.
o Block work systems:
Interlocking concrete masonry units (CMU), and lightweight concrete blocks.

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2.2 Barrier to implementation of IBS in Malaysia
2.2.1 Lack of participation from small contractors

From the survey it is found that many small contractors are unwilling to implement IBS system
and tend to continue using the conventional method of construction. This is because small
contractors are already familiar with the conventional system and they do not exposure self more
to IBS. Moreover, they run small scale projects with conventional method and therefore not
willing to change to mechanized based system (Azam J. et al., 2009).

Besides, small contractors are short of financial backup and are not able to run their own
manufacturing plants as it involves very exhaustive capital investment. A successful adoption of
IBS construction system partially depends on heavy and special equipment such as cranes. The
high preliminary cost in setting up the manufacturing plant with addition of the cost of
transportation has cut down the margin of profit. Still a large portion of the construction industry
players still has a biased perception on IBS system even though they aware that IBS has a lot of
advantages. However, switching to IBS would not guarantee considerable savings in the cost
especially with the small volume of buildings constructed. Therefore, financial issues become the
foremost hindrance for small contractors to advance with the IBS system (Azam J. et al., 2009).

2.2.2 Negative perception on IBS

Rahman & Omar (2006) observed that the term IBS is often misinterpreted with negative image
due to its past failures and unattractive architecture.

These buildings are usually related with pre-fabricated, mass construction method, low quality
buildings, leakages, abandoned projects, obnoxious architectural appearances and other
drawbacks. Due to the poor architectural design, the old pre-fabricated buildings have been often
badly impressing public about pre-cast concrete. Clients are often hesitating to use IBS as they
fear that customer will reject. Even construction professionals are wavering in IBS technology
and relate IBS with a prospective post-construction problem. In addition, it is always not popular
among the designers as they found pre-fabrication has limiting their creativity in design process
(Hamid et al. 2008).

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It is noticeable that the end user are neither misinterpret nor unaware of this construction method
because IBS is lacking of branding and promotion taking place in the market. Hence, IBS is not
bringing enough attention from end users and creating more demands to encourage developers to
adopt IBS. In comparison, IBS development in Scandinavian and Japan focus more on
customer’s interest and demand and adopt mass customization of to enrich customer option. In
UK, sustainability and green construction are associating well in IBS. To be concluded, most
projects constructed with IBS in Malaysia were low quality and high construction cost while
exploitation of IBS in Japan and Sweden are so successful due to projects constructed with IBS
are high quality and high productivity (Azam J. et al., 2009).

Consequently, better customer perception will create better understanding and demand and will
definitely encourage developers to push for IBS adoption (Azam J. et al., 2009).

2.2.3 Loose supply chain integration

Construction is a multi-organization course of action, which involves client/owner, designer,

contractor, supplier and consultant. It also is a multi-stage course of action, which includes
conceptual, design, construction, preservation, replacement, and decommission. By moving
construction activities upstream from the construction site to factories where pre-assembly is
carried out, high demands will be raised on the management of the supply chain and logistic
activities (Pan et al. 2008) (Blismas, 2007) (Gibb, 2001).

In such arrangement the risk involve with any construction quality and tolerance are also clearly
identify and the party responsible for taking corrective action is agreed from the outset of a
project. Extensive integration requires good IT tools to ensure supply chain continuity and
synchronization. Integration also includes developing supplier partnership and establishes clear
information flow using IT (Oostra & Jonson, 2007).

However, the current state of construction industry is being considered as fragmented where the
whole supply chains get their own strategy and agenda. To worsen the situation, IT adoption in
Malaysia is still low and contribute to loose supply chain coordination and integration between
design and manufacture which is vital to IBS implementation.

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2.2.4 Lack of awareness and poor knowledge on IBS
i. Client

Due to lack of awareness program, client always misinterpret that IBS is high risk and expensive
solution and this leads to lack of interest from the client and decision makers. IBS always be
considered as last solution for fast track construction in larger projects e.g. Jaya Jusco, Tesco etc.

Promoting IBS to public is needed so that client with a good knowledge and awareness of IBS
benefit will encourage appointed designers to design building in IBS as they may demand for
fast track construction by using IBS (CREAM & CIDB, 2010).

ii. Designer

Project delays may be caused by lack of knowledge among IBS designers as the technology may
limit the ideas or designs from designers for mass production. More time is needed by designer
to produce detailed drawings (CREAM & CIDB, 2010).

iii. Local Authorities

Approving authorities with poor knowledge may delay the process design approval as majority
of authorities is not aware of IBS design and takes more time in consideration. Moreover, they
usually misunderstand and misinterpret of IBS and its relation to the current building regulation.

Approving authorities need to be familiar with IBS to speed up design approval as it is vital to
ensure successful IBS project (CREAM & CIDB, 2010).

iv. Policy Makers

It is also observed by Chung & Kadir (2007) recently that of local authorities in Malaysia are
unlikely to change local building regulation to suit IBS as the amendment will consume a lot of
time and cost.

According to IBS Mid Term Review (2007), the enforcement of Modular Coordination (MC)
trough the amendment of Uniform Building by Low (UBBL) is yet to be implemented due to
poor knowledge and awareness on this concept among the policy makers (CREAM & CIDB,
2010).

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 v. Workers

Dependence on foreign workers is planned to be reduced by 30 percent by 2015. However, most

industry people doubt that large number of workers in the industry can be reduced by IBS as they
think that IBS is just taking the problem from a job from site environment to a factory
environment. Therefore, there is still a need of wet-trade workers. This is wrongly interpreted as
a IBS manufacturing factory can produce the components to several projects which running at
same time. Compared to IBS, conventional method will require more workers by given same
situation. However, lack of skilled local workers is a common problem because of mismatch
between the training the CIDB provides and industry needs (CREAM & CIDB, 2010).

2.2.5 Improper planning and failure in considering IBS at the design stage

IBS is always being considered as alternative method. Current, the pre-casters and contracting
firm in Malaysia are taking part after tender stage of the construction value chain. The IBS
design should be addressed and planned from design stage of the project so that it would be
successful adopted through the integration of pre-caster, designer and contracting firm and not
through proposing alternate design.

It is observed that most projects in Malaysia are not cost effective as changing in design causes a
lot of further adjustment that increase the initial time and cost. When IBS is implemented at
design stage, it will solve a lot of issues related to manufacturing, transportation and logistics as
everything is pre-planned ahead of time.

To avoid improper planning on IBS, IBS needs more consistent structure of process planning and
control from start to end of the project in order to reduce defect and errors and reach the goals
and satisfactions. The overall project is needed to be planned in the way as after the components
are manufactured, those components can be transported to the construction site and assembled
without delays or difficulties. Any delays will give severe impact on staging requirement and
production planning where all components from several construction projects are planned for
production at the same time. The most common issues in assembly of the components are

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normally involving the beam-to-column and column-to-base connections due to improper
planning and coordination at design stage (Azam J. et al., 2009).

2.2.6 IBS seems to be more expensive compared to traditional method

Compared to traditional method, IBS seems to be slightly expensive choice so traditional method
becomes more appealing option to decision makers in Malaysia. Besides, pre-casters or IBS
component manufacturers have to invest high initial capital to purchase new machinery, mould,
importing foreign technology and wages of skilled workers for installation process. Furthermore,
because of wide swing of housing demand, uncertain economic condition and high interest rate,
IBS becomes more unattractive choice.

Small and medium class contractors might view IBS as risks to their business. When using pre-
fabricated components in IBS project, client is required of paying upfront deposit in advance to
procure the components. So, the cash flow of existing payment will be totally affected over
project progress system. Hence, using IBS will be feared by small and medium contractors
instead of thinking it as opportunities (Azam J. et al., 2009).

2.2.7 Mismatch between the readiness and the roadmap among designers and contractors

IBS has been agreed and accepted as a supreme conceptualization and simplifying construction
work. However, distance between practical idealism and reality in project in Malaysia is far
apart. The transformation is not green a good respond due to the unlikely construction readiness
(Hamid et al. 2008). Highly skilled workers are always being needed to replace foreign workers
for superior construction but contractors have no other choice as that local workforce is
unwilling to join the industry because of the issues of low wages combined with occupational
safety and health being lowly stressed on. The current training program to produce new
construction workforce is still not be able to cater vast demand of the market.

Despite of foreign worker policy, the industry still badly require foreign labor to do labor-
intensive job and it is available abundant in cheaper cost. Moreover, intensive training and

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apprenticeship are needed for specialized skills such as system integrator or assemblers and these
require more time and investment. Contractors in Malaysia are not exposed much to IBS and
their professional has no well technically knowledge in this area (Hamid et al. 2008). Besides
that, lacks of research and development, low IT implementation and limited technology
accessibility have negatively contributed in IBS take up. On the other hand, it is pretty expensive
and difficult for local contractor to purchase that most innovative system and components or
using innovative materials as they are based on imported technologies (IBS Roadmap Review,
2007).

2.2.8 Technical issue related to IBS

One of the biggest issues for IBS implementation is the inclination to show construction failure.
It is much because of improper installation by untrained constriction workforce and relatively
wet climate in Malaysia. Most companies usually bring in foreign workforces who are willing to
be paid low. Those foreign workforces are mostly untrained or unknowledgeable on IBS.
Trained workforces in IBS would demand higher wage for their works and skills compared to
untrained workforces. Therefore, construction failure by using IBS would always happen as
improper installation by unskilled workforces.

Besides that, renovation works are hardly carried out as it is constraint by the pre-cast system
design and also the M & E system. This causes IBS system not popular choice for developer and
customer because the majority of house owner in Malaysia have tendency to renovate their
dwelling at some point of their tenancy (Azam J. et al., 2009).

2.3 Recommendation

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To push IBS implementation in Malaysia, some improvements are recommended to solve current
problems.

First, the role of contractor has to be reengineered or reallocated. In the process of IBS
implementation, the contractors are required to integrate the project’s overall system and act as
coordinator of managing process from production line to site. This process is highly emphasizing
on new skills and knowledge such as integration, planning, and monitoring. Without those
managing skills, an IBS project may face huge risk of uncoordinated error and tolerance and
cause cost inefficient. Therefore, reengineering role of contractor is obligatory when transform
from traditional method to IBS. Integration role between design and product production needs to
be implanted in professionals’ skill (Azam J. et al., 2009).

Second, awareness programs on construction technology should be restructured. Establishment

of more inclusive awareness programs and showcases of best practices such as road shows or
exhibitions will help IBS to be more understood by public and encourage more industry people
to widely use IBS. Besides, it is essential that new awareness programs have to be organized
periodically to educate or update all the stakeholders to IBS. Hence, construction engineering
related person such as engineers, contractors, university lecturers should be more encouraged to
attend to IBS awareness activities such as seminar, workshops to allow them exposed more to
IBS and they may also help to introduce IBS to client and encourage client to use IBS.
Moreover, mass-media communication and site visit to real manufacturing factories or project
site will help to expose IBS to stakeholders. More importantly, the awareness program must be
able to support two-way communication between the promotion agencies and the stakeholders so
that stakeholders can clearly understand and avoid negative perception on IBS (Azam J. et al.,
2009).

Third, current IBS training program must be restructured. More detailed preliminary study or
survey should be conducted by the government to specify and clearly identity skills gaps or skill
shortage in IBS in order to create a more inclusive and organized training program. Then, with
help of preliminary study, the training will be ensured to fit or satisfy the needs of IBS
organization and accommodate current skill shortages in the market mainly on specialization
skills such as design and installation based on information from real practice. When comes to
design, it is challenging part for engineers or architects to must have competent knowledge in

16
component analysis and IBS building design. Being responsible in construction field, contractors
and site engineers must have enough knowledge on safe and accurate methods of erecting and
assembling IBS components into a building structure to avoid design coordinating failure (Azam
J. et al., 2009).

Fourth, ICT adoption should be enhanced. Accurate and reliable information exchange is vital to
better IBS implementation in project. Wide and extensive range of processes in IBS projects can
be managed and coordinated well by help of Information Technology (IT). Those processes are
such as customer interfacing, design, production, monitoring and integration. Multitasking on
different IBS process can be supported well by extensive use of modern IT tools and it enabling
good accurate documents. Errors especially in design and coordinating can be discovered early
and problems in the manufacturing and assembly phases can be avoided when doing overall
checking. This turns to be good condition for effective production. Besides that, utilization of IT
in IBS projects allows clients to do better analysis, cost comparison, design selection,
communication between clients and contractors by providing more accurate and updated data
(Azam J. et al., 2009).

Fifth, R&D focus on IBS should be restructured. The insufficiency of evidence based scientific
research undertaken to authenticate the benefit of IBS system need a new advance to be taken on
board. Establishment of long term and strategic approach of conducting research on IBS should
be done with strong involvement of universities, companies, organizations right from the onset
of any IBS R&D projects. R&D themes should involve wide area such as development on hard
issues e.g. jointing system, IBS material and also include inclusive study on IBS solutions
covering the whole value chain. Research on developing verification progress, IBS related
software, vendor developing system, marketing system, building concept, IBS safety procedure,
IBS whole life cycle costing, lean construction concept and developing financial model for IBS
firm is also included to enhance efficiency of IBS (Azam J. et al., 2009).

Last, negative perception or bad image on IBS should be changed through rebranding. In
Malaysia, IBS construction is being branded as cheap and fast but it turns to be poor strategy as
it bringing out many failure in past, improper installation and poor design due to cost reduction
mentality. As a result, instead of pulling customers’ interest, it distracts customer. Now, the
strategy should be changed to attract customers with high quality of IBS products instead of cost

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reduction. More importantly, IBS should be branded as the value for money solution with quality
and environmental friendly solution to overcome issues of sustainability, carbon footprint and
global warming. Moreover, IBS design should be enriched with lifestyle aspect where designers
will gather customer input and generate a design based on customer’s request or opinion.
Development of more showhouse also will showcase the building components and emphasizes
its feature as a holistic sustainable building of future of houses. Thus, this will not only draw
interest from new buyers and widen new market ranges but also improves the overall image of
construction industry (Azam J. et al., 2009).

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3.0 Is Sarawak ready to use Industrialized Building System (IBS)? State your opinion.
Refer to state planning unit or Malaysia plan which part that related to Sarawak.

3.1 Introduction
Although Sarawak had starting to use Industrialized Building System (IBS), many contractors
and consultants in Sarawak are still lacking in term of knowledge and wholly exposure in IBS.
According to the design executive of Sarawak Consolidation Industries Berhad (SCIB), Chong
Kian Chiang, SCIB is the earliest IBS company in Kuching. It started on the year of 2005. It is
followed by the Cahya Mata Sarawak (CMS). For future information, Hume Sdn. Bhd. will also
start in the year of 2011. It will help IBS in Sarawak to improve or develop more rapidly.
Bluescope Lysaght in Bintulu is also another example of IBS companies in Sarawak.

A lot of current housing projects, public and private buildings, infrastructure projects are using
IBS. For instance, The Spring , Kuching International Airport, UNIMAS hospital and Pusat
Islam in Kuching, and shop houses at Petrajaya Sibu. Kidney Dialysis Centre in Kuching, it used
pre-cast concrete framing. The building has six storey and 3, 000 m 2 of floor area. It took less
than five months to be completed. Their IBS components are provided by the company as
mentioned previously. For the components that usually used and produced by IBS companies in
Sarawak are hollow core slab, column, beams (first floor beam and roof beam), ground slab, half
slab, hollow core panel wall and etc.

The most common IBS in Sarawak is pre-cast system. All of the IBS components can be done in
factories or on the site are considered pre-cast. About 70% of Sarawak construction project use
IBS pre-cast system. The residue 30% use in-situ work. Consequently, IBS is less in
consumption of man power. The installation of IBS components is done by specific professional
worker. They are trained to install the IBS components by referring to the drawing. They have
been trained by some institutes in Malaysia like local Construction Industry Development Board
(CIDB) and Institut Kemahiran MARA (IKM). These two companies play an important role to
train a small group of skilled worker into the construction projects using standard IBS
components (5 components) such as Steel Formwork System. Consequently, local workers in
Sarawak can be trained as skilled workers to use IBS.

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Basically, construction of IBS consists of various processes. First of all, the foundation of the site
is completed to proceed to installation of IBS system. Before that, the IBS components are
transported or delivered to the site. The IBS components like column, beam and hollow core slab
are lifted by gantry crane to lorry or big truck and then travel to the site to store them as nearer as
to the site. The IBS components are installed by crane. Columns will be installed first and
followed by beams. They are connected by dowel bars. After that, the void space surrounded by
the dowel bars is filled in with non-shrink grout to connect column and beam stronger. The half
slab will be installed later. The slab will be laid with concrete topping after that to make the floor
more perfect. Finally, fast wall is installed. It is lighter due to capacity in structure. It has hollow
space inside the wall. So it is easy to handle and has better insulation. The roof also can be built
using steel framework but it is still not familiar to Sarawak contractors.

Construction of IBS needs a lot of skilled workers and consists of various processes in
installation and involves many parties and different stages of work. The efficiency of the project
needs the cooperation of various sectors including contractors themselves. They must be familiar
to IBS system so that the construction can be ran and conducted easily. Consultant also must
give a full set of guideline to engineers, contractors, workers, etc since they still not really
expose much to IBS.

3.2 Research methodology

This paper is a preliminary study about Sarawak is whether or not started to use Industrialized
Building System (IBS). This paper has divided into few parts so that the question can be found
out easily at each part. We chose to had site visit rather than seeking out information through
internet only. This allows us to expose directly to real IBS on site. Our group had conducted a
site visit to Sarawak Consolidation Industries Berhad (SCIB) on 26 January 2011. We made an
interview to design executive, Mr. Chong Kian Chiang on the site visit. He gave us many
important issues, information and knowledge about IBS. He taught us the process of product of
IBS components. Besides that, Mr. Lee also showed us around the factory and machine of IBS.
However, we had still search and used some information from internet to expose ourselves to the
extras knowledge on IBS more detail.

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3.3 Advantages of using IBS system
The term of cost, time, quality and safety are all related to the IBS advantages. By applying IBS
to the construction process it will become more simplified. This is because the main components
are already prepared nicely from factory. Labors just install the column, beam, slab, etc. So it
helps to cut down the production time. Building construction will be faster in process as it
reduces site works. This is one of the opportunities for the industry to save more times to
construct the building which also take a role in project life cycle.

One of the objectives of IBS techniques is to reduce the numbers of foreign workers hired. IBS
system may apparently reduce workers as it does not need extra site works. Moreover, it helps
the site to reduce man power. By off-site components manufacturing, several dozen on-site
workers can be reduced to usually about 5 to 6 people workers for off-site works such as precast
construction. Fewer labors will reduce the cost of construction. It saves the client budget in
practice.

In terms of quality, IBS concept is done with a standard procedure. A quality controlled product
can be produced as the production is done by skilled and knowledgeable workers. Off-site
manufacturing can make it easier for quality controlled to be through strictly as it is done in the
factory and the environment is suitable compared to on-site. As a matter of course, IBS is
increasing better quality control and low maintenance cost. The components produced by high
strength of material so that it will be more durable. Products appearance and finished is one of
the advantages’ aspect in using IBS. Various types of components with different finishes can be
produced by the manufacturer to get a good structure appearance according to architectural
design. By this, compare to traditional method it will produce a better product appearance.

Another advantage of IBS system is it can also stand a greater load capacity. On the other hand,
it will give a longer life span to the structure. As it reduces extra site works, cleaning and
clearing of site wastage can be minimal. Plus it can avoid the steel bars stolen cases at site. IBS
system apparently gives some advantages in order to innovate Malaysia construction industry.

21
3.4 Barriers to industrialized building system (IBS): the case of Malaysia

IBS is not popular among design consultants

Lack of knowledge among designers

The need for mindset change through promotion and education

The stakeholders face a chicken and egg dilemma

Lack of support and slow adoption from private sector

Proprietary systems make it hard to be adopted by designers

Poor quality products available in Malaysia

Joints are not standardized making it hard to design as the

design will have to be fixed to a particular manufacturer

Lack of push factor for authorities and responsible government

bodies by laws and regulations

The professionals in Malaysia is lack of technical knowledge

about IBS components

Volume and economy of production in scale IBS components

Monopoly of big boys, limiting opportunities to other

contractors

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 (Source: Barriers to industrialized building system (IBS): the case of Malaysia, January 2009,
http//www.cream.com.my/publications/whitepapers/abstract11)

3.5 Problems that need to be overcome for implementing IBS in Sarawak

Sarawak also is facing the same problems as the case of Malaysia above but Sarawak has more
specific and serious conditions need to be solved immediately so that the IBS system can be fully
implemented in Sarawak. First of all, the road condition in Sarawak is not good. It has some
limitation for transportation to be applied only at city area. This is because the rural area road
commonly is soft soil. Truck and crane are hard to go into rural area. Consequently, IBS project
only limited to urban area.

Apart from that, IBS system is only suitable for commercial and hospitalize projects and not
suitable for small residential housing project. This is due to the mass production of column size.
The column is considered too big for being used by residential housing project. For example,
600×600 mm column.

Moreover, the cost of some IBS components is more expensive compared to the conventional
one. For instance, the hollow core wall panel is 70% more expensive than brick wall. Normally
the brick wall is cost RM 0.25-0.30 per piece. So many contractors prefer to use brick wall
instead of hollow core wall panel.

Besides that, Sarawak is easy to get cheap labors from Indonesia and Philippine. Many
contractors prefer to adopt conventional method compared to mechanical method (IBS). They
would like to employ a hundred of labor from Indonesia rather than using IBS system. The cost
of labor from Indonesia is very low and it costs about RM 10 per day. So contractors can save
more cost if using the conventional way. According to design executive of Sarawak
Consolidation Industries Berhad (SCIB), Chong Kian Chiang, cost of pre-cast is about 25% more
expensive than in-situ formwork. He also said that reusable formwork is also considered as IBS
system. In addition, due to high capital of machinery makes the cost of IBS components more
expensive. According to SCIB’s design executive, the cost of a column is roughly about RM
2000+ and the hollow core slab (250 mm in thickness) is cost RM 102-136 pre meter square.

23
3.6 Factors of IBS Not Popular In Sarawak

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3.6.1 Student less expose to precast knowledge

From the previous to the present, still, students are less expose to detail knowledge of precast.
This phenomenon may due to the lack of awareness of society in Sarawak to expose themselves
to such field. This in turns causing the graduates to face difficulties in differentiating the design
methods of precast. As a result, IBS system is getting less popular for Sarawak peoples to
implement in local construction field.

3.6.2 Consultants are not familiar with IBS

Knowledge of implementing IBS in Sarawak start lately if compares to west Malaysia. Based on
the information provided by Mr. Chan, SCIB is the pioneer of starting IBS in Sarawak at 2005
following by CMS at 2010 and Hume Sdn. Bhd. Start at 2011. Without proper and fully
exposure to IBS, currently many consultants know nothing much about IBS and they do not dare
to take the risk by implementing IBS which is an unknown to them.

24
3.6.3 In-situ formwork is cheaper than IBS

Due to technologies needed for implementing IBS, its expenditures are far more expensive than
conventional construction method ones. According to Mr. Chan, workmanship of in-situ
formwork is very cheap whereby the salary is expected to be RM300.00 per Indonesian worker.
While for IBS system, skilled worker may require expensive cost.

3.6.4 IBS require guidance from professional engineers

Without a doubt, IBS system requires proper skill and detail knowledge to be start of. Therefore,
it is essential for a professional engineer to guide the firms or companies to implement IBS in
their projects.

3.6.5 Sarawak is a strategic place for laborer

As Sarawak is located near to Indonesia and Philippine, it gives Sarawak a better chance to
employ cheaper workers from those countries. This economical phenomenon has greatly
attracted the industries in Sarawak to use the conventional construction method rather than to
adopt IBS system.

3.7 Solutions
First of all, the road condition need to be improved in Sarawak to make sure the transportation of
IBS components be accessible to rural area. This is because road of rural area is mostly soft clay.
So this soft clay will cause big dump truck cannot enter to that area certain area. If road
condition improved to bituminous pavement, contractors would consider using IBS system rather
than choosing conventional way.

Apart from that, production of IBS components can be improved so that clients can get the
stocks easily. The quality control need to be insured so that they will trust and purchase IBS
components continuously. The production of IBS components should also cope with the
demands in Sarawak. With these perfect resources for contractors or clients, they will more

25
prefer to use IBS system.

In addition, the IBS components should make in different of sizes. Due to certain factory like
SCIB only product or offer larger size of IBS components like pre-cast column of size 600×600
mm. So that small project like residential project cannot get the smaller size of pre-cast column,
beam, etc.

The cost of IBS components should produce in large quantity so that it will more economical in
costing. Government should help small IBS industries with support of lowering tax on some
expensive machinery. For example, slab saw machine, extruder machine, slipformer machine,
etc. This will make small industries is affordable to buy those machines and able to expand more
rapidly and increase the competitive in Sarawak.
Lastly, some institutes in Malaysia like local Construction Industry Development Board
(CIDB) and Institut Kemahiran MARA (IKM) have play an important role to train a small group
of skilled worker into the construction projects using standard IBS components. However, this is
still not enough in Sarawak. Government should build more institutes in Sarawak so that local
workers can be trained straight in Sarawak.

3.8 Conclusion

In fact, Sarawak may be has some problems to execute IBS. This is due to the delay of IBS
implementation such as IBS is still not popular among design consultant. IBS is considered as
new component for them. Sarawak still needs more time to recognize IBS. Moreover, lack of
knowledge among designers also makes some delay of implement IBS. Professional designers
are needed to conduct IBS. They should be able to design using software like Microsoft Project
and ACAD. Consequently, designers in Sarawak need for mindset change through promotion
and more education in IBS.

26
 Figure 10: Steel Frame

Figure 11: Precast concrete column

27
Figure 12: Precast concrete column

28
REFERENCES:

Abdullah, M. R., Kamar, K. A. M., Nawi, M. N. M., Haron, A. T., & Arif, M. (2009).
Industrialised building system: A definition and concept. Paper Proceedings in ARCOM
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2011 from: http://www.cream.com.my/publications/whitepapers/Arcom.pdf

Azam J., Hidayah, Sharon, Syafiq, & Ooi (2009). Industrialised building system (IBS).
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Kementerian Kewangan Malaysia: Surat pekeliling Perbendaharaan Bil. 7 Tahun 2008:

Pelaksanaan IBS dalan projek kerajaan: IBS roadmap (2003-2010) (2003). Construction
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Ping, T. S., Omran, A., & Pakir, A. H. K. (2009). Material waste in the Malaysian construction
industry. The International Conference on Economics and Administration, Faculty of
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APPENDIX A

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