Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and

Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

INDUSTRIALISED BUILDING SYSTEM (IBS): REVISITING THE ISSUES ON DEFINITION, CLASSIFICATION AND THE DEGREE OF INDUSTRIALISATION
Kamarul Anuar Mohamad Kamar, Mustafa Alshawi, Zuhairi Abd. Hamid, Mohd Nasrun Mohd Nawi, Ahmad Tarmidzi Haron, Mohd Rofdzi Abdullah Construction Research Institute of Malaysia (CREAM), CIDB MALAYSIA The Research Institute for Build and Human Environment (BuHu), UNIVERSITY OF SALFORD

ABSTRACT: Industrialised Building System (IBS) is the term to represent the prefabrication concept in Malaysia. The term was invented to shift from the typical paradigm of prefabricated systems. IBS has been introduced as a method with better productivity, quality and safety. This has managed to create a better response from the industry. However, the move towards industrialisation of construction industry is a global phenomenon and not merely a local or isolated initiative. The definition and classification of IBS need to be evolved and incorporated with global views and understanding. This paper revisits the issue on definition, classification and the degree of industrialisation. A conceptual definition and classification has been proposed in this paper based on literature reviews. Again, IBS needs to be associated with innovation and best practices in construction. The classification of IBS should be expanded to cater for the scope of volumetric (modular) and hybrid construction. Better understanding on IBS and its degree of industrialisation will move IBS away from the prefabrication stigma. It is hoped that the concept highlighted in this paper will encourage positive debate on IBS and gain some attention from the practitioners and researchers at large Keyword: Industrialised Building System (IBS), definition, classification, degree of industrialisation

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

1.0

INTRODUCTION

IBS is a technique that uses pre-fabricated components or off-site installation, where project clients and developers can gain benefit from many ways. Construction Industry Development Board (CIDB) of Malaysia has published a definition for IBS and its classification which has been widely used as common understanding by researchers and practitioners in Malaysia (CIDB, 2003; CIDB, 2007; Hamid et al, 2008; Kamar et al, 2009; CIMP, 2007b). The definition and classification are as follows: Definition: IBS is a construction technique in which components are manufactured in a controlled environment (on or off site), transported, positioned and assembled into a structure with minimal additional site work Classification: 1. 2. 3. 4. 5. Pre-cast Concrete Framing, Panel and Box Systems Steel Formwork Systems Steel Frame System Prefabricated Timber Framing Systems Block Work System

However, the move towards industrialisation of construction industry is a global phenomenon and not merely a local or isolated initiative. The definition and classification need to be evolved and incorporate with global views and understanding. The definition and classification of Off-site Construction (OSC), Modern Method of Construction (MMC), Off-site Manufacturing (OSM), Off-site Production (OSP), pre-assembly and prefabrication are worth to be examined. It gives us a different perspective and enriches our understanding on IBS concept as whole. Numerous descriptions of the Industrialised Building Systems (IBS) concept have been highlighted by local researchers and all of the definitions stressed on prefabrication and mass production. The term and classification were often misinterpreted as a system limited only for construction of buildings. It can be defined as an approach or process used in making construction less labouroriented and faster as well as fulfilling quality concern (Shaari & Ismail, 2003). The broader view of IBS is about the changing of conventional mindset, championing human capital development, developing better cooperation and trust, promoting transparency and integrity (ibid). Firstly, the paper will revisit current definition and classification on IBS. Secondly, it will review other terms to describe IBS in the literatures. Thirdly, the conceptual definition and classification will be developed and finally, the paper reviews IBS and its relation to a degree of industrialisation. With the issues of global competitiveness, productivity and quality, global industry players are revisiting IBS as a tool in achieving better performance. IBS should provide clear understanding on its etymology and classification.

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

2.0

REVISITING CURRENT IBS DEFINITION

The paper revisits the definition of IBS from 20 literatures of local and international researchers from 1971 2009. The definitions are listed on the following Table 1:
Table 1: List of Definition of IBS

The following analysis has been derived from Table 1: In general IBS definitions have been classified into two categories: o IBS as a method, approach and process o IBS as a product, system and technology Fifteen authors have defined IBS as a method, approach and process. On the other hand, only five (5) authors defined IBS as a product, system and technology and these include the definitions from notable international researchers (Asko Sarja and Alexander Warszawski) From the table, the definitions consist of six (6) different characteristics of IBS; industrialised production, transportation & assembly technique, onsite fabrication, mass-production, structured planning & standardisation and integration While almost all literatures mentioned an offsite technology or factory production as an important attribute for IBS, definition by CIDB, (2003), Chung (2006) and Shaari & Ismail (2006) highlighted onsite technologies in IBS All definitions cover at least 2 or 3 characteristics of IBS. Definition by Chung (2006), however, covers 5 out of 6 characteristics listed on the table. The definition by CIDB Malaysia (CIDB, 2003) which has been widely used in Malaysia has not covered the aspects of mass-production, structured planning & standardisation and integration in its definition. Those characteristics, however, are essential as highlighted by other researchers Regardless of the terms, the idea of IBS is the same which is to move some effort away from the construction site to a more controlled environment of the manufacturing floor. The paper, however, suggests that the new definition on IBS should consists of both the process and system point of view, as well as all six (6) characteristics highlighted on the table

3.0

OTHER TERMS USED TO DESCRIBE IBS

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

Many different terms are used to describe industrialised construction and prefabrication. Pre-assembly, prefabrication, Modern Method of Construction (MMC), Offsite Construction (OSC), Offsite Manufacturing (OSM) and Offsite Production (OSP) are terms in common use at various times in the literatures. The following Table 2 highlights the definitions to describe the industrialisation of construction industry:
Table 2: Other terms used to represent industrialisation in construction

Modern Method of Construction (MMC) is a term adopted in the UK as a collective description for both offsite based construction technologies and innovative onsite technologies. The former represents prefabrication and manufacturing technology and the latter includes techniques such as thin-joint block work and tunnel-form construction (Goodier & Gibb, 2006). In definition, MMC includes both industrialised and non-industrialised innovation. Non- industrialised innovation is the use of innovation method that has been seen in other industries including carpet reinforcement, metal shutters, core jump systems, double jumping cores, edge protection systems and service walls (BURA, 2005). The paper concludes that not all MMC is IBS, but all IBS is under MMC. IBS in definition is a process in which component are manufactured, positioned and assembled into a structure with minimal additional site works both off-site and on-site (CIDB, 2003). Offsite and manufacturing technique is essential to IBS but onsite IBS method can be used in the form of in-situ pre-cast system using steel formwork (ibid). Thus, the paper concludes that all offsite is IBS, but not all IBS is offsite. The other term used to describe IBS is prefabrication. Prefabrication is a manufacturing process generally taking place at a specialised facility, in which various material are joined to form a component part of final installation (Tatum et al, 1986). Some prefabrication can be done onsite (onsite fabrication). Offsite

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

construction however, is a description of the spectrum or part there of which are manufactured or assembled remote from building site prior to installation in their find position. In this family, Offsite Construction (OSC), Offsite Manufacturing (OSM) and Offsite Production (OSP) are largely interchangeable terms which refer to that part of the construction process which is carried out away from the building site, such as in a factory or sometimes in specially created temporary production facilities close to the construction site (or field factories) (Goodier and Gibb, 2006). While, the components maybe are assembled onsite and offsite, preassembly literally means to assemble before and covers the manufacture and assembly (usually off-site) of buildings or parts of buildings earlier than they would traditionally be constructed on-site (Gibb & Isack, 2003). Thus the offsite can be divided into preassembly and onsite assembly. The relations are best shown in the following Figure 1:

Figure 1: IBS and other terms to describe industrialisation in the method of construction

4.0

ESTABLISHING A WORKING DEFINITION OF IBS

From the above list of definitions the more generic definition of IBS can be derived as the following: IBS is an innovative process of building construction using concept of massproduction of industrialised systems, produced at the factory or onsite within controlled environments, it includes the logistic and assembly aspect of it, done in proper coordination with thorough planning and integration

5.0

IBS CLASSIFICATION

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

Just as the definitions, IBS has a various different classification which is based on material, process and system. Table 3 shows the classification of IBS, building system, MMC and OSM.
Table 3: Comparison of IBS-MMC Classification

For further exploration of and discussion between researchers in this field, a generic classification for IBS is derives as the followings: 1) 2) 3) 4) 5) 6) 7) Frame System (pre-cast or steel) Panellised System Onsite fabrication Sub-assembly and components Block work system Hybrid System Volumetric and Modular System

The classification is based on CIDBs IBS classification which is well known in Malaysia, with an important addition of hybrid and volumetric (modular) system.

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

Both are essential systems in MMCs classification. Onsite fabrication term is used to replace steel formwork system. This is to move away from the prefabrication image of formwork system at site. The precast concrete framing, prefabricated timber framing system and steel framing system is combined under the term frame system for simplicity reason. This term is also used in MMCs classification. Roof truss, balconies, staircases, toilets, lift chambers are classified under sub-assembly and components. This is a move to promote in-fill and skeleton concept which is an interesting concept in open system. It is hoped that IBS classification can be standardised in the future in order for IBS to be accepted by practitioners as a primer construction method.

6.0

IBS AND THE DEGREE OF INDUSTRIALISATION

Industrialisation is a part of a wider modernisation process through the development of modern methods of production and technology system, mainly factory production where work is centrally organized, production operations are mechanized and are focused on mass production (Lessing, 2006). The degree of industrialisation is an indicator to measure the level of industrialisation adoption. It also represents the maturity of IBS adoption. The degree of industrialisation is shown in Figure 2:

Figure 2: Degree of Industrialisation (Richard, 2005)

Prefabrication is a manufacturing process generally taking place at a specialised facility, in which various material are joined to form a component part of final installation (Tatum et al, 1986) Mechanization comes in whenever machinery is employed to ease the work of the labour

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

Automation is a situation when the tooling (machine) is completely taking over the tasks performed by the labour Robotics comprises the ability of the same tooling which has the multi-axis flexibility to perform by itself diversified tasks. This allows the masscustomization concept. Reproduction implies that research and development of innovative processes are truly capable of simplifying the production process To be successful in IBS, we need to move away from prefabrication towards the level of mechanisation, automation, robotics and finally reproduction. Prefabrication can be as high as mass-production of components in factory to as low as using steel formwork onsite. If one still practices prefabrication and the government still encourages the use of low technology solution, the evolution of industrialisation could be static and the effort to promote mass-customization could be jeopardised. Mass-customisation concept and open system as highlighted in IBS Roadmap 2003-2010 (CIDB, 2003) can only be adopted through automation (Richard, 2005). IBS practitioners need to continuously search for new strategies as well as new technologies to increase the degree of industrialisation. The government and the policy makers should find solution to assist the industrial revolution and eventually stop promoting low-tech onsite prefabrication which gives little benefit to the practitioners. This degree or level of industrialisation is also associated with the scope of work in the construction process or life cycle. As compared to the traditional method, the prefabrication scope of work involves more planning. On the other hand, the prefabricated scope of works is less than the mechanisation approach in term of tasks involved. The tasks covered by mechanisation which integrate the architectural work (painting, ducting, finishing) are done in factory earlier before the mobilisation to site. While prefabrication is the process of joining the components of panels and this becomes an element of building, the mechanisation level is applied to the process in the factory by machine. The automation level utilises the programmable machines like robotics to perform the tasks including the computerised tools for planning, design and operation.

Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

As compared to the traditional method, the prefabrication involves the planning stage. The role of manufacturing in the project life cycle is increased with the degree of industrialisation. Above all, when industrialisation is concerned, the earlier a decision is made the better so the production team can plan to schedule the work of prefabrication. In the prefabrication, mechanisation and even automation degree of industrialisation, one can change the design in planning phases. This is because the prefabrication can start during the planning and execution stage of the project life cycle. But for robotics and reproduction, the design shall be determined as early as the conceptual stage. By understanding the degree of industrialisation, one can plan the IBS project cycle and accommodate its manufacturing element as early as the conceptual phase of the project. One can also understand the risk of IBS where, any late change on design within the implementation stage can present a disaster to the whole project

7.0

CONCLUSION

Industrialised Building System (IBS) is the term to represent the prefabrication concept in Malaysia. The term is invented to move away from the typical paradigm of prefabricated systems. This paper proposed the definition, classification and its relation to other terms used to describe industrialised construction and finally discussed IBS and its degree of industrialisation. The paper has concluded the following: IBS definition should incorporate all six (6) characteristics from existing definitions which are industrialised production, transportation & assembly technique, onsite fabrication, mass production, structured planning and standardisation and integration

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Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

IBS should be seen as innovation in construction. The innovation agenda has been promoted in the UK under the MMC and offsite constructions umbrella. It is imperative that IBS is seen as an evolution of construction using new and innovative techniques rather than a revolution. The classification of IBS should be expanded to cater the scope of volumetric (modular) and hybrid construction. IBS is not to be seen as a threat to traditional methods. Both methods should be able to work in tandem and improve their processes collectively. The sharing of best practice between the two approaches is essential for the continued successful development of both construction sectors. IBS should move up the degree of industrialisation from prefabrication to reproduction through innovation. The mass-customisation concept which is vital to open building system agenda can ONLY be achieved through the adoption of automation in the level of industrialisation The more advanced IBS is in the level of industrialisation, the more roles IBS has to be involved in project life cycle. The reproduction level of industrialisation will involve the whole project life cycle from planning to maintenance. IBS can be seen as a solution to the whole project life cycle if ONLY, it can achieve reproduction level of industrialisation The generic definition and classification had been proposed in this paper to engage positive debate into it and to obtain constructive reaction from practitioners and researchers. It is hoped that the definition and classification will enhance our understanding of IBS.

8.0

ACKNOWLEDGEMENT

The authors are grateful to the Construction Industry Development Board (CIDB) and the Construction Research Institute of Malaysia (CREAM) for sponsoring this research project. The research is a part of R&D collaboration between CIDB, University of Salford and University Teknologi MARA. The researchers under the IBS Research Theme in University of Salford are Kamarul Anuar Mohamad Kamar (CIDB), Mohd Rofdzi Abdullah (Universiti Teknologi MARA), Mohd Nasrun Mohd. Nawi (Universiti Utara Malaysia) and Ahmad Tarmizi Haron (Universiti Malaysia Pahang).

9.0

REFERENCE

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Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

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Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

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Kamarul Anuar Mohamad Kamar, Alshawi, M, Zuhairi Abd Hamid, Mohd Rofdzi Abdullah, Mohd Nasrun Nawi and Ahmad Tarmizi Haron (2009), Industrialised Building Systems (IBS): Revisiting the issues of definition, classification and degree of industrialisation, paper proceedings in 2nd Construction Industry rd th Research Achievement International Conference (CIRAIC), 3 4 November 2009, Kuala Lumpur, Malaysia

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