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syurga7181@yahoo.com
cesanusi@eng.usm.my
cewan@eng.usm.my
ABSTRACT
The traditional methods of construction industry have made the appropriate initiative to make a paradigm
shift in the prefabrication construction in order to achieve a higher standard and to adapt to the global business
trend. This review paper present the challenges faced by the construction industry to integrate the
prefabrication construction with the existing traditional method and to make the comparative study among the
three countries; United Kingdom, Australia and Malaysia. Malaysia applied industrialised building system
(IBS) which is defined as a construction system where components are manufactured at factories on or offsite, transported, and then assembled into a structure with minimum work. IBS involves prefabrication and
installation of components at the construction site. While, modern method of construction (MMC) is the term
used by the United Kingdom government to describe a number of innovations in house building. However,
offsite manufacturing (OSM) is the term used for Australian and UK construction industries. This research
studies the pattern of MMC, OSM and IBS to identify the pattern research scholars in the three countries and
precast concrete system become popular system. Conversely, to highlight the important role of the
government and researcher in educating the construction industry players and to transform the construction
industry into a modern and efficient industry
Keywords: Industrialized Building System (IBS), Modern Method of Construction (MMC), Off-site
Manufacturing (OSM), IBS components, pattern of off-site
1.0 INTRODUCTION
The building sector has yet to undergo a complete phase of industrialization. Yet, if a car
was produced the way a building is delivered, very few people would be able to own one;
if a computer was produced the way a building is delivered, it would cost a fortune
(Richard, 2005). This demand can be met by means of the advanced technology used in the
Industrialized Building System (IBS) or prefabrication system. Malaysia possesses the
hardware elements of the industrialized building systems technology with only a little
concern on the structure, but still lacks the software elements regarding availability of
data and information on the system, users, clients, manufacturers and assembly layout and
process, as well as allocation or resources and material (Badir et al., 2002). Most of the
construction industries have the resources but still lack on the constructability concepts and
the advanced technology that can enhance the speed of construction, improve the quality of
the structure and be able to protect the environment.
However, the concept of constructability started in the late 1960s to integrate the optimum
use of construction knowledge and experience in the conceptual planning, detail
engineering, procurement, and conduct field operations in phases to achieve the overall
ISSN 2232-1309 2012 Royal Institution of Surveyors Malaysia
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project objectives; and ease of construction (CII, 1986). The constructability concept has
been extensively developed and applied in UK, Australia and Malaysia where numerous
studies have proved that constructability concept manage to save cost and time in the
process of completion of the projects (Nima et al., 2001, Trigunarsyah, 2004, Wong et al.,
2007).
The construction industry has currently been transformed into a mass production to develop
standardisation of products in line with the global market. The Malaysian government is
aware of the importance of developing a capable construction industry, which has to be
driven by technological developments in a manufacturing and service industry able to
contribute to the economy. In Singapore, a great concern was stated in the C21 report (reinventing construction) that highlights the blue print of their construction industry which
reported the most recent review of the state of the construction industry. The report
identifies six strategic thrusts requirement for Singapore to become a world-class
construction industry and Dulaimi et al. (2004) find out that Singapore is seen to lag behind
from Australia, Japan and the United States in the performance of the construction industry.
Hence, the six strategic thrusts are enhancing the professionalism of the industry, raising
the skills level, improving industry practices and techniques, adopting an integrated
approach to construction, developing export capabilities, and developing export
capabilities. This strategy affects the Malaysian construction industry in terms of learning
the added value from countries that have achieved global recognition, such as the United
Kingdom and Australia.
On the other hand, prefabrication is a manufacturing process generally taking place at a
specialize facility, in which various materials are joined to form a component part for final
installation (Tatum, 1986). But on the other hand the prefabrication process could also run
onsite (onsite fabrication). While off-site construction is a description of the spectrum or
part which are manufactured or assembled remote from building site prior to installation in
their final position (Goodier and Gibb, 2007a). Thus prefabrication is use by the term offsite construction as well as Modern Method of Construction (MMC); Off-Site
Manufacturing (OSM) and Industrialized Building System (IBS). The definitions for the
term MMC, OSM and IBS have the interrelated concept of prefabrication and onsite
fabrication (Azman et al., 2011a).
This paper is divided into four sections. The first two sections explain the principles
underlying the improved performance in manufacturing by illustrating some similarities to
the construction industry in the UK and Australia. The third section assesses the principles
of IBS in Malaysia by highlighting the role of government in educating the construction
industry players. The final section reviews the pattern research in the three countries in
terms of similarities and differences.
2.0 MMC IN UK
The UK government initially learned the manufacturing system from Japan through the
Toyota concept (one of the largest car manufacturers in the world) that builds Toyota
Homes for house manufacturing in 1975 (Gann, 1996). The concept gave added value to
the customer by having both properties made by Toyota. Gann (1996) visited Japan eight
times between 1990 and 1995, along with ongoing collaborative research between UK and
Japanese researchers on the innovation in the construction sector. In the 1940s, Toyota
came out with a new approach on the organisation of production, the use of plant,
management resources, quality control, and relationships between producers and
costumers. Womack (1990) identified that approach as the new system of mass production
which is more efficient and responsive and named it lean production.
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Researcher analysed the problem encountered on OSM usage in the construction industry,
and recognised future investment and research to dissolve setbacks (Blismas, 2007). OSM
is similar with Off-Site Fabrication, Off-Site Production, and Off-Site Construction in
terms of pre-assembly and prefabrication (Goodier and Gibb, 2005, Pan et al., 2005).
However, for consistency in using the construction term in Australia, OSM was used
because this was the term used in the Construction 2020 Report (Hampson and Brandon,
2004).
Goodier and Gibb (2005) experienced some difficulties in tracing the historical value of
OSM in Australia. There were vague boundaries that existed between some traditional and
OSM approaches, as well as data reported on the performance of construction and
manufacturing industries. Blismas and Wakefield (2008) performed a qualitative survey
using the methodology in Australia as basis to study the state-of-the-art OSM. Eventually,
the approaches of research in OSM are merely web research, workshops, interview survey,
and case studies. Based on the comparative analysis, the main theme for the drive and the
constraint for OSM includes skills and knowledge. The OSM industry is expanding and
will have a great demand of trade skills workers. Moreover, the industry is experiencing a
change in focus on the explored alternate procurement and the vital assessment for logistic
and site operation of OSM.
In a further research attempt, Gibb (1999) produced a categorisation of OSM where the
system groups are broken down into four levels associated with the degree of off-site work,
as indicated in Figure 1. Thus, Table 1 also shows the pattern and the degree of technology
changes. Azman et al. (2010a) stated that the US, UK and Australia have achieved the
modular building standard but Malaysia is still in the initial stage to achieved it. The three
countries have the similarity in off-site preassembly but UK and Australia have divided the
off-site preassembly into non-volumetric and volumetric order. Thus, UK and Australia
share the same similarity categorization of off-site system where most of the Australian
researchers referred to UK.
4.0 IBS MALAYSIA
In Malaysia, the industrialised building system (IBS) was initiated in 1964 by the Housing
and Local Government after capitalising on the success of several European countries
(Thanoon et al., 2003). The players in the industry preferred to use the conventional method
until the Construction Industry Development Board (CIDB) educated the industry on the
essential usage of IBS components and conducted awareness programs on the usage of IBS
since 1998. It is as a way to overcome one of the major problems in Malaysia i.e. delay of
construction projects, construction waste and foreign labor problems. With the intention to
adopt the increasingly rapid technological changes,
IBS is expected to play a greater role in ensuring improvement in construction activities
and sustainable economic growth. This has improved in the first quarter of 2010,
Malaysias economy achieved a growth of 10.1%. Manufacturing and construction were the
two major sectors which showed an increase growth of 16.9% and 8.7% respectively
(MITI, 2010).The CIDB has conducted three IBS surveys, in 2003, 2005, and 2008, where
the respondents were contractors and architects (Majid et al., 2010). The survey recorded
recent trends in IBS components system, and showed an increasing number of
correspondents that gave a good response on grounds of using IBS as reflected in the
achievement of IBS usage in the building construction in Malaysia.
The commitment of the government in encouraging the use of this approach can be seen
with the development of the Roadmap IBS 20032010. The Roadmap aimed to provide
Level
Category
Component
manufacture &
sub-assembly
Non-volumetric
preassembly
Volumetric
pre-assembly
Modular
building
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Definition
No
Countries
US
Author
Lu (2009)
UK
-Non-volumetric preassembly
-Volumetric pre-assembly
-Modular building
-Non-volumetric preassembly
3
50
Project Duration
Applied technology
Transportation
requirement
Erection Procedure
Crane requirement
Environmental
Awareness
Type of workers
Traditional
Construction
Manufacturing
Project-based
Short term
Project-based
Short term
Product-based
Long term
Profit in volume of
similar products
(Gann, 1996)
Long period
Possibility of project
being delayed
(Lim and Mohamed,
2000, Alagbari et al.,
2007)
On time project
completion/meeting
timeline
(Kadir et al., 2005)
Manually
Higher mechanisation
due to process
repeatability and highquality production
Not important
Important
Very important
Manually
Not required
3-D Syndrome (Dirty,
Difficult, and
Dangerous)
Requires unskilled
worker
Occasionally required
Occasionally required
Very important
Very important
Environmentally friendly
and recycled waste
faster project completion, (7) neater and safer construction sites, and (8) lower total
construction costs (Majid et al., 2011). There is no doubt that for the initial stage, an initial
investment for IBS requirement ensures long-term return by mass production.
Consequently, the IBS component has also undergone changes since the early 60s until
2010, following the new trend of technology described in Table 3. In addition, creative and
innovative ideas are needed in improving the use of IBS components through the use of
appropriate technology suitable to the Malaysian climatic conditions as finally achieved the
six categorized in 2010. Similar to the ancient world, construction materials are made to
adapt to the climatic condition, natural resources, and collective local skills, as well as
having the ability to comprehend the performance characteristics of the construction
materials (Ngowi et al., 2005).
Conversely, CIDB had implemented the IBS Score in the construction industry to measure
the level of IBS usage in buildings and become part of the main monitoring system of the
IBS construction industry. In the 2005 Budget, the policy on the usage of IBS components
in Government building projects increased from 30 percent currently to 50 percent
commencing 2005. Housing developers who utilize IBS components exceeding 50 percent,
will be given full exemption on the levy imposed by CIDB (Budget, 2004).
Furthermore, based on the impact of the UBBL in using MC in the construction industry
and the Government ruling that require the contractor to use IBS components, all public
buildings in 2008 are required to achieve the 70% IBS Score at the minimum (Treasury,
2008). While for the private residential buildings, the contractor need to acquire a minimum
of 50% IBS Score to qualify for an exemption of construction levy for the project. The
scoring system is made accordingly to the principle of usage of prefabricated and precast
components, off-site production of components, the use of standardized components,
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IBS Introduce in
Early 60s
Categorization
of IBS
Badir et al.
(2002)
Early 90s
Badir and
Razali (1998)
2003
CIDB (2003)
2010
CIDB (2010)
IBS Component
i.
ii.
iii.
i.
ii.
iii.
iv.
i.
ii.
iii.
iv.
v.
i.
ii.
iii.
iv.
v.
vi.
Frame System
Panel System
Box System
Precast concrete framing, panel and box
systems
Load bearing block
Sandwich panel
Steel frame
Pre-cast concrete framing, panel and box
systems
Formworks systems
Steel framing systems
Prefabricated timber framing systems
Block work systems
Pre-cast concrete systems
Formworks systems
Steel framing systems
Prefabricated timber framing systems
Block work systems
Innovative
repeatability and design building component based on the Malaysian Standard Guide to
Modular Coordination in Building, MS 1064.
Based on the evolution of IBS components and extension types as well as the imposed of
the government policy, the number of IBS manufacturer and IBS products has also
increased. The most popular IBS components used in the construction industry are precast
concrete system and followed by formwork system and steel framing system, as described
in Figure 2. The number of IBS manufacturers has gradually increased from 75 (in 2009)
to almost twice the number as reported in IBS Info 2010 (Azman et al., 2009).
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United
Kingdom
All
Review
Buildings
only
Waste
Malaysia
Production
Sustainable
All off-site
products
Structure
Australia
Manufacturing
Research
Perceptions
Products
Innovation
Countries
Supply Chain
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In contrast, Malaysia is much focus in applied the IBS in all types of buildings especially
for the government project where will received exemption of tax. However, the benefits of
IBS technology is not limited for buildings only but also admitted in the infrastructure
where able to retain high repetition IBS components. However, UK and Australia applied
the prefabricated construction in all types of projects which is not limited to the building
only.
Moreover in the implementation of policy; Australia and Malaysia had enforced the
construction industry players to use prefabrication construction while for the UK is still in
the encouragement stage of using prefabrication construction. From these facts, the
collaboration of government and researchers have played vital roles to educate the main
players of the construction industry in the form of policies, financial incentives, strategy
guidelines, workshops and seminars to increase the awareness among the end users and
clients.
6.0 CONCLUSION
To establish IBS, MMC, and OSM in the construction industry, all participants must
acquire knowledge on the current technology in the construction industry. This is necessary
for Malaysia to compete globally and adjust to the current economic changes. The industry
should also respond and cooperate with the government initiative encouraging OSMs, and
embark on research work to increase the standards of the construction industry. The
experience and problems faced in setting up OSMs should be shared. An exchange of
knowledge to motivate and educate other countries to move to a higher level of
development for the construction industry must also be pursued.
Thus, IBS have the similarity drive and challenge with the United Kingdom (UK) and
Australia; and among the factors are skilled craft worker, fast track completion, cost and
transportation. The three factors that determine the ability of construction industries to enter
the international market are technological advantages that are associated with possessing
formidable construction technologies; sophisticated management systems for scheduling,
material tracking, organized sub-contractors; and financing capability that enables a
company to arrange for project financing schedules from international financiers.
Technology is an important tool to push the construction industry to achieve the
international level. This will help construction companies to achieve long-term profitability
and acquire a balance growth in the future.
The trend in the prefabrication construction industry pattern has gone through a few
transitions from the conventional method to the prefabrication stages. Precast concrete
system is the most popularly used in the IBS industry as well as for the UK and Australia
scholars have stated to encourage applied the precast concrete system as proposed by
Lovell and Smith (2010) and Blismas and Wakefield (2009a). This research manages to
determine the pattern prefabrication construction, physical and social factors for
implementation IBS, MMC and OSM.
ACKNOWLEDGMENT
The authors wish to thank the Construction Industry Development Board (CIDB), Malaysia
and Universiti Sains Malaysia (USM) for the providing the data.
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