IBS - CIDB Malaysia

IBS and Mechanisation As
Sustainable Method in Construction
Ir. Dr. Zuhairi Abd. Hamid
Construction Research Institute of Malaysia (CREAM)
Discussion Points
•
•
•
•
IBS Roadmap 2003-2010 & Goals
Cabinet approved
on October 29, 2003
•
Reduction of dependence on
foreign labor.
•
Improvement in quality, productivity,
safety, and competitiveness in the
construction industry.
•
Generate new economic growth - IBS
component industry through Open System
IBS Roadmap 2003 – 2010
1.
The Roadmap is a comprehensive document that divided
the IBS programme into the five main focus areas that
reflect the inputs needed to drive the programme
2.
Each beginning with with a letter M. They are:
a.
b.
c.
d.
e.
Manpower,
Materials,
Management,
Monetary, and
Marketing
Why market is not responding enthusiastically to the
programme of industrialising the construction industry?
•
Changing mindset: Achieving acceptance by the construction community.
This is by far the most difficult problem. Many in and out of the
construction industry still have the perception that IBS is rigid and not
flexible enough in both form and dimension to meet all the variable
demands of construction. This leads to the mistaken conclusion that IBS
can only produce monotonous design.
•
The cost of using IBS exceeds the conventional methods of construction,
especially given the ease of securing relatively cheap immigrant labour,
•
The risk of trying an unfamiliar technology is too high compared to
current profit margin in construction,
•
IBS design concept is not being taken into consideration at the onset of
the project,
•
Designers will not design using components as they do not find the
components in the market, whilst producers will not produce components
as they do not see designs using components
IBS – Why market are not responding?
• In a highly competitive industry such as
construction where profit hovers around
5 – 10 % and risks are extremely high
will a contractor substitute proven
methodology with unproven techniques
such as IBS which can easily blow out
the 5 – 10 % profit?
IBS Roadmap 2003 – 2010
Potential hurdles to the implementation of the Road Map:
•
•
•
•
•
Developing and sustaining market demand for IBS
sufficient to generate economies of scale for its
industrialisation
Development of standard plans and standard component
drawings for common use,
Apprentice and on-the-job training in the area of IBS
moulds and casts, and assembly of components,
Vendor development program, and
Readiness of designers and consultant practices
Industrialised Building Systems:
The way forward – Malaysia’s experience
(2010 -2015)
Type 1: precast concrete
PC columns, beams, slabs, 3Dcomponents (balconies, staircases,
toilets, lift chambers, box girders,
etc)
Type 2: formwork system
Tunnel forms, beams and column
moulding forms, permanent steel
formworks (metal decks), etc.
Type 3: steel frame system
Steel beams and columns,
portal frames,roof trusses, etc
Type 4: prefabricated timber frame systems
Timber frames, pre-fab timber roof
trusses, etc.
IBS VIDEO
Type 5: block system
Interlocking concrete masonry
unit (CMU), lightweight
concrete blocks, etc.
IBS Roadmap 2011-2015 & Goals
Approved by the Cabinet on July 9,
2010
•
Maintain commitment and momentum
70% IBS content in government projects
until 2015.
•
Increases in the use of IBS in private
projects to the extent of 55% by 2015.
“A construction technique in which
components are manufactured in
a controlled environment (on or
DEFINITION
OF Industrialised
off
site), transported,
positioned
building system
and assembled
into(IBS)
a structure
with minimal additional site
works”
Comparison:
Offsite construction – UK
Modern Method of Construction - MMC
What went
wrong?…
What must be
done to speed up
adoption of IBS…?
Development of IBS in Malaysia
IBS Pilot Project:
Flat Pekeliling,KL
& Flat Riffle
Range, P.Pinang
IBS
Strategic
Plan 1999
IBS Roadmap 2003-2010
Construction Industry Master Plan
2006-2015
Cabinet
Approved
Malaysia IBS
International
Exhibition
’06 (MIIE06)
IBS
Roadmap
Review
2008-2010
Malaysia IBS
International
Exhibition
’09 (MIIE09)
Malaysia IBS
International
Exhibition
2011(MIIE’11)
1999 2001 2003 2004 2005 2006 2007 2008 2009 2010 2011
2013
Manual for IBS
Content Scoring
CIS18 2010:
Diterbitkan
1966
IBS
Roadmap
2011-2015
MS 1064: Modular
Coordination as a
guide in the design of
building
Treasury Circulars
on July 25, 2005
Treasury Circular on
October 31, 2008
“Promotion”
“Mandate”
Cabinet approved
the Cabinet on July
9, 2010
Benefits of Adopting IBS
Increasing the Speed of Construction
• Well planned IBS project has been proven to
shorten construction time, thus reducing
financing costs of the project and causes
less pollution
• Malaysia will be more competitive with
speedier constructions
Outflow of Money
Less Foreign Labour
• Foreign labour sends money back to
respective countries, a major loss of
revenue to the country.
• With less foreign labour, the outflow of
money could be reduced.
• The reduced outflow could be channeled
Intangible
benefits of
adopting IBS
• Use of IBS would encourage less site
construction workers thus reducing the
dependency for foreign labour
to better use in developing better IBS
products
Reduced Social Issues
• Social issues that are related to foreign
workers can be reduced because of the
reduction in dependence on them
IBS VIDEO
Effectiveness of IBS against conventional
Means based on most likely figures from study
Majority of construction contracts / expenditure is
in the private sector.
Construction
Contract
78.55b
43%
Government
57%
Private
33.77b
44.78b
31%
6%
Residential
1.84b
61%
Non Residential
20.72b
33%
Infrastructure
11.21b
Construction Contract/ Expenditure in 2009
Residential
13.69b
49%
Non Residential
21.83b
20%
Infrastructure
9.26b
enforce
standardisation to
enjoy economies
of scale…
…economies of scale required
Pool of Cheap
Foreign Labour
• A pool of foreign workers available for the
construction industry
• Relatively cheaper alternative than investment
in machinery and tools that can improve
productivity
Small Manufacturers Base
Low adoption of IBS
• Huge capital required for start-ups
• Large variation in fulfilling orders, not inline
with idea of mass production concept of IBS
components
• Expansion limited by availability of people with
IBS know-hows (i.e in interpreting non
standardised designs into shop floor
specifications)
Challenges to be
addressed in the
new roadmap…
Lack of Volume in IBS Industry
• Low adoption = low volume = inefficient level of
production= uncompetitive prices
• Low volume compounded with non standardisation of
orders (example : UBBL encourages use of modular
concept but does not mandate it, individual local
authorities have different requirements)
• Why change when there is still a pool of low cost
foreign labour?
• IBS is more expensive than conventional
methods of construction, diversion from
conventional methods seemed to be driving
profits away for builders
• Contracts are still awarded primarily on
competitive pricing
• Lack of awareness of the benefits of IBS
mandate adoption
of IBS in private
sector…?
IBS Penetration
high%
70%
scoring for
all RM10m
projects
50%
scoring for
all RM10m
projects
Fast Track
Option for
Private
Sector
Policy Driven
Sporadic
developments
using IBS
low
Fast Track
option for
government
projects
Policy Driven
Dayabumi
Pekeliling
Flats
1970-s
Treasury
IBS
Circular
Strategic 2005
Plan
Policy Driven towards
50% in 2015?
$$
Treasury
Circular
2008
Incentives given
to private sector in
2007
1999 2005 2008
Realistic
option for
Private
Sector
58 IBS
projects?
Market driven adoption while
government prepares
industry for policy driven
measures post 2012
Incentive
Manufacturing
Base development
today
2012
Market driven
track may take
longer
Enforcement
of Standards
Structured
Decrease
In Foreign Labor
2015
Time
2020
DEGREE OF INDUSTRIALISATION
High
Robotics
Reproduction
Automation
Mechanisation
Prefabrication
(IBS)
(ROGER BRUNO RICHARD, 1998)
Low
Estimated value creation of product
driven industrialization
NEED FOR MECHANIZATION IN CONSTRUCTION INDUSTRY
1. The work can be done speedily.
2. The work can be done in time.
3. Large quantity of materials can be handled, so the size of the project can be
increased
4. The complex projects involving high grade material.
5. High quality standards can be maintained.
6. Time schedule can be kept.
7. Optimum use of material, man power and finance.
8. Due to shortage of skilled and efficient man power.
I
M
P
A
C
T
Labour Reduction
Cost
Quality
Safety
Speed
Increase Productivity
Characteristic of Mechanisation
Implement product
standardisation
High product
quality and
standard
Machineries
operate by
operators
Reduce tradesmen
and improve
productivity
Ease and fast
production
Optimum use of
material,
manpower and
finance
Mass production
Better working
condition
TRADISIONAL METHOD OF
SLAB CONCRETING
MECHANISATION
ROBOTIC
3D TOILET MODULE (POD)
Preparing for the future of
prefabrication in Southeast Asia:
Sustainable & Affordable Housing
Quality & Supply
Modular Housing
Latest
Malaysia Economic Plan reported that the building industry is
required to construct at least 100,000 affordable housing units
a year. That means to completed at least 300 housing units a
day starting now!
But
our present housing design strategies are unable to cope with
the incredible demands on such massive scale in sustainable
manner……
The Fact is
an Eco-friendly house costs 15% more expensive than the
conventional one, and is always presumed to be a preserve
of the wealthy……
How
do we design and build an affordable and sustainable house?
PRINCIPLE 2 – DESIGN FOR FLEXIBILITY
A Flexible Design
“A flexible design can respond
to events, even when they
unfold in unpredictable ways.”
ONLY FLEXIBILITY CAN
SUITE ALL THE DESIGN
should be able to:
• incorporate sustainable elements;
• make possible the application of the latest
design ideas and technologies;
• optimizing the energy uses;
• promoting resource efficiency;
• improving the indoor environmental quality
(IEQ)
• facilitate the movement towards
mechanization, industrialization, and
standardization
ECO-HOUSING SOLUTION FOR URBAN POPULATION
D3 =
Divergent
Dwelling
Design
With the same model, same structure, and same construction,
D3 has more than thousands of possible combinations.
Each of which is of high level of flexible form and function in
architectural organization with sustainable manner – capable of
continuous modification, renewal, and redesign
D3 – Divergent Dwelling Design System
•
The D3 system is an alternative to the currently
applied convergent housing design system.
•
It aims to solve the problem of rising demands of
houses and the current architectural strategy.
•
It advocates the green design principles and
practices in the country’s construction industry.
•
It aims to facilitate the movement of construction
industry towards mechanization and volumetric.
Conventional Design Initiative
•
•
•
•
•
•
•
Rigid structure
Interlocking plan
Predetermined function
Top-to-bottom approach
“One fits all” design strategy
Extreme compartmentalization
Dissociation of internal elements
In general, it tends to consider more on the
physical development of housing rather than
on the sustainable inhabitation
D3 – Divergent Dwelling Design System
Stair
FUNCTION =
Bath
Kit
COR
unit
Flexibility is D3
D3 is Flexibility
The Formation of D3 Sustainable Living Unit
1
Independent COR unit &
various service spaces
4
Formation of community or
township with D3 system
Various Service Spaces
2
COR
unit
3
Service spaces attached
externally to COR unit
Various configurations of
typical dwelling units
ECO-HOUSING SOLUTION FOR URBAN POPULATION
D3 =
Divergent
Dwelling
Design
has it possible to apply traditional construction techniques
to urban housing.
It promotes the potential of using the traditional system as
an alternative construction system towards sustainable
urban development in Southeast Asia.
A Typical
Kampung
House
D3 Design
Process
Typical kampung house
Extracting traditional design
wisdom for the construction
of modern urban sustainable
dwelling
D3 FlexiHome
D3 > 10,000 Plans
Space Lot
> 10 NOS
Floor Plan
> 10 NOS
Service Plan
> 10 NOS
Compound Plan > 10 NOS
Various
Plan
Various
Arrangement
D3 aims to bring forth sustainability into the
mainstream of construction industry
Divergent
Dwelling
Design
Mechanization,
Modernization,
Mass production
Simple, Standard,
System
D3
+
M3
+
S3
ECONOMY
SUSTAINABILITY
ENVIRONMENT
SOCIAL
49
How Maximum Flexibility is achieved?
Living spaces with high degree of flexibility,
able to adapt to the occupant’s changing
lifestyle, and ensuring the minimum
reconstruction, renovation, or costs
associated for the future adaptation, are
made feasible in through the application of
“sunken floor” and “interstitial space”.
Interstitial
Space
Sunken Floor
D3 > 30% Energy Saving
D3 > 50% Faster
D3 > 50% Faster
D3 > 100% IDU
ECO-HOUSING SOLUTION FOR URBAN POPULATION
D3 =
Divergent
Dwelling
Design
make possible
Less Cost More Quality
Less Time More Quantity
Less Wastage More Green
Less Resources More Performance
–
DARE TO IMAGINE
A joint initiative project of CREAM-G&A Architect-MBAM-REHDA
“4-storey
walk-up flat”
Divergent
Dwelling
Design
(D3)
“Single storey
terrace house”
“2-storey
terrace house”
THANK YOU