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50  • Concrete Engineering International   October 2012

In line with current housing demands inthe global market, the construction indus-try has shifted its focus to mass produc-

tion assembly and standardising productdevelopment. This strategy has promptedthe Malaysian construction industry to re-evaluate the achievements of other coun-tries in implementing prefabricated technol-ogy, such as the UK, Australia, Singaporeand Hong Kong.

Prefabrication technology in Malaysiais called IBS, alternatively known as mod-ern methods of construction (MMC) oroff-site manufacturing (OSM). Azman et

al(1)  reported that the IBS concept is simi-lar to MMC in the UK. OSM is used both inAustralia and the UK construction industry,while prefabrication is used in Hong Kongand Singapore.

IBS has been promoted since the 1960sbut the construction industry in Malaysiahas stuck to conventional methods. Thishad a negative impact and delay in the

implementation of projects. Hence, in1994 the Malaysian Government set up theConstruction Industry Development Board(CIDB) to educate the industry.

Since 1998, CIDB had implemented the‘IBS Score’ to measure the level of IBS usagein building. Based on CIDB requirements, allpublic buildings are required to achieve aminimum of 70% IBS Score, while for private

residential buildings, contractors need toacquire a minimum of 50% to have exemp-tion from the construction levy for projects.The scoring system is in accordance with theprinciples of standardised usage of prefab-ricated and IBS components, repeatabilityand design building components based onMalaysian Standard 1064(2). Consequently,there has been a high demand for precastconcrete among contractors and a quali-tative survey was carried out to study theestablishment of precast manufacturingsites and the criteria for setting up suchplant.

MethodologyThe research methodology applies a quali-tative approach through a series of inter-views and observation. The collected data

were interpreted and coded into an effec-tive number of categories. Currently, 25 IBSprecast manufacturers are registered withthe CIDB in Malaysia. A population surveywas conducted through interviews with 15decision makers (top management level)from precast manufacturing plants with fiveyears’ experience in IBS work.

Setting upThe coding data of 15 respondents havedetermined the relative frequency of fourmain themes in setting up precast manu-facturing (Figure 1). The relative frequency

themes are able to describe the rudimentarymeasurement of the relative importance ofthe precast manufacturing industry:

 Appropriate technology The appropriate IBS technology for theconstruction industry in Malaysia is hybridi-sation – a combination of a small partialconventional method with mechanisationtechnology. It reflects the latest IBS clas-sification of innovative systems. Together,the Government and the research scholarshave produced a guideline on the off-site

system. The categories, pattern and thedegree of technology changes are describedin Table 1.

Transportation/erectionThe size and weight of completed pre-cast units may limit the design and theseaspects need careful design consideration.The length of a volumetric unit should notexceed 12m, the normal vehicle length. TheIBS components’ height should not exceed4.5m when loaded on the trailer; the compo-nents could not enter the highway system ifthey exceed a height limitation ranging from

4.8 to 5.1m. The precast concrete compo-nent should not exceed 7 tonnes to ensurethat a crane can easily erect and transportthe material on-site. The suitable distance ofany potential development area to the fabri-

 A study of precast concrete in Malaysia 

Malaysia has attempted to transform its conventional method of construction to prefabrication usingindustrialised building systems (IBS) and changing productivity from project based into product based. Themost common IBS component used in Malaysia is precast concrete. This article describes a qualitative study

conducted on 15 decision makers from 25 Malaysian precast manufacturers registered with theConstruction Industry Development Board (CIDB).

Mohamed Nor Azhari Azman, Sultan Idris Education University, Tanjong Malim;

Mohd Sanusi S Ahamad and Taksiah A Majid, Universiti Sains Malaysia, Nibong Tebal;

Mohd Nazree Shah Anwar Shah, Wisma Global Globe, Kuala Lumpur; – all Malaysia

Countries Categorisation

Off-site preassemblyUS  Hybrid system  Panellised system  Modular building

Component manufacture and  subassemblyUK Non-volumetric preassembly  Volumetric preassembly  Modular building

Non-volumetric preassemblyAustralia Volumetric preassembly  Modular building

Precast concrete systems  Formwork systems  Steel framing systems

Malaysia Prefabricated timber framingsystems

  Block work systems  Innovative product systemsSource: Azman et al (2010)

Figure 1: Relative frequency of themes in

setting up precast manufacturing.

PRECAST CONCRETE

Table 1 – Categorisation of off-site system

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Concrete Engineering International   October 2012 • 51

cation plant should be from 50 to 100km, based on the study madeby Warszawski(3). It is also important to have the precast concretein parts. This partial size can be ‘plugged and played’ to enhancethe effectiveness for the erection of the IBS components. Figure 2shows the typical sequences of the IBS working system.

All IBS components are built with hooks for easy handling anderection as shown in Figure 3. The lifting and installation of IBScomponent units requires a high level of skill and careful safety

planning. The lifting points should be matched to the distributionof the weight of the unit to ensure that the item will be lifted on alevel plane.

Design and build The best practice tender award for IBS system is ‘design and build’.The design-and-build method is able to control the whole projectflow, especially during the construction period, with less changesin the design stage.

Under the IBS method, M&E drawings must be prepared in theearly stages. The process requires consultation with the client tofinalise the design. The effectiveness of the IBS drawing helps toeliminate redundancy in conventional works, especially during thesuperstructure stage.

Construction workersMost of the developed countries are keen to reduce foreign work-ers’ input in their production of commodities. IBS implementationcan be part of the strategy of labour reduction and effective train-ing to acquire local skills. Therefore, with the IBS implementation,Malaysia has reduced the number of foreign workers by 4% in 2006and is able to better educate the industry on the appropriate use ofIBS technology and systematic work to gain the same productivitywith better outcomes.

PRECAST CONCRETE

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ResultsThe end result of the contentanalysis has proposed 11 criteriafor permanent and mobile pre-cast manufacturing plants. Thesignificant difference betweenpermanent and mobile precastmanufacturing is the movability ofthe precast manufacturing plant.The main structure of permanentprecast manufacturing is a per-manent building with full cover,

shaded or semi-shaded to provide protec-tion from weather conditions, while mobileprecast manufacturing has a contrastingphysical structure as shown in Figure 4.The detailed comparison of permanent andmobile precast manufacturing is illustratedin Table 2(4).

ConclusionPrefabrication has been successfully used inthe manufacture and construction of housesand multi-storey industrial buildings.

The main parameters affecting the set-ting up of precast manufacturing factoriesare: appropriate technology; capability oftransportation and erection of IBS compo-nents; best practice in design and build; andskilled workers.

Appropriate technology is vital in accel-erating the development of a country andrepresents major factor in setting up precastmanufacturing.

In addition, this study presents an outlook

of 11 criteria for setting up precast manufac-turing site plants, ie, permanent or mobilemanufacturing. The results have providedan indication that the construction industrymust move towards new criteria.

The IBS technology must be affordableand future research should be continued forthe benefit of the construction industry.■

■ Further information:More details on the IBS Score can be found at:www.ibscentre.com.my 

■ References1. AZMAN, M.N.A., AHAMAD, M.S.S., MAJID, T.A.

and HANAFI, M.H. The Common Approach in Off-Site Construction Industry. Australian Journal

of Basic and Applied Sciences, Vol.4, No.9,pp.4478–4482, September 2010.

2. DEPARTMENT OF STANDARDS MALAYSIA,MS 1064.Guide to Modular Coordination in

Buildings: Part 1: General Principles. StandardsMalaysia, Kuala Lumpur, Malaysia, 2001.

3. WARSZAWSKI, A. Industrialized and Automated

Building Systems. E & FN Spon, London, 1999.4. AZMAN, M.N.A., AHAMAD, M.S.S., MAJID,

T.A. and HANAFI, M.H. Permanent and MobileIndustrialised Building System ManufacturingPlant Based on Malaysian Case Study.Proceedings of the World Conference on

Information Technology, Antalya, Turkey,Academic World Education & Research Center,2011.

52  • Concrete Engineering International   October 2012

Figure 2 left: Typical IBS systemsequence of works.Figure 3 right: Hooks of the IBS

components.Figure 4 below: Typical mobile

model of precast manufacturingplant.

PRECAST CONCRETE

Criteria Permanent manufacturing Mobile manufacturing 

Annual project RM100 million above (US$33m) RM10 million above (US$3m)Capital High LowTechnology Prefabricated, semi-auto, automatic PrefabricatedMaintenance High maintenance: Low maintenance:

High electricity bill Low electricity billLand capacity Minimum 15 acres Can start with 5 acresMould Flexible size Flexible sizeRoof of IBS Permanent MobileManufacturing Protected from rain Develop portable roofing to  protect the concreteManpower Maximum 500 workers 25 workers  Specific task Multi-tasking  High payment Low paymentProduct Hollowcore slab Half slab  Half slab Staircase

Staircase BeamBeam ColumnColumn Wall panelWall panel

Crane Permanent Permanent or mobile

  At factory: 25–30 tonnes At factory: 25–30 tonnes  At site: 50–260 tonnes At site: 50–260 tonnesConcrete Required batching plant concrete Outsource or set up a new

batching plantSource: Azman et al(4)

Table 2 – The comparison of permanent and mobile precast manufacturing