Near optimum selection of module configuration for efficient modular construction

doi:10.1016/j.autcon.2017.03.008

Automation in Construction

Volume 83, November 2017, Pages 316-329

https://doi.org/10.1016/j.autcon.2017.03.008 Get rights and content

Highlights

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A new systematic tool for near optimum module selection is presented.
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Modular Suitability Index (MSI) is introduced to assess and rank the suitability of alternative module design configuration.
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MSI includes the effect of five developed indices.
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The developed indices are; (CI), (TDI), (TSDI), (CCPI), and (CVI).
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Reducing number of module connections is cost efficient.

Abstract

Modular construction gained considerable momentum over the last decade due to its positive impact on project cost, schedule, quality, and safety. Current literature in this field focused on cranes selection and scheduling methods, without due consideration for optimum module configuration. This paper introduces a novel modular suitability indicator which utilizes five indices; 1) connections index (CI) to evaluate module connections using the matrix clustering technique, 2) transportation dimensions index (TDI) to evaluate module dimensions' effects on transportation, 3) transportation shipping distance index (TSDI) to evaluate the distance between manufacturing facility and the construction site, 4) crane cost penalty index (CCPI) to evaluate the crane cost relevant to the module placing rate, and 5) concrete volume index (CVI) to evaluate the project's foundation concrete quantities. Calculating the modular suitability index (MSI) provides a unified indicator to accomplish a near optimum selection of module configuration for efficient delivery in residential construction.

Introduction

Offsite construction systems vary depending on the size of prefabricated components which affect the need for onsite construction. These systems include many categories such as modular, panelized, prefabricated, and processed materials construction. Blending two or more of these categories results in a “hybrid” offsite construction system. Each category has its own unique configuration based on its own constraints such as transportation, manufacturing, and onsite lifting and positioning limitations. Choosing between the use of any offsite construction system depends on project characteristics and its targeted cost, schedule, and the scope of off-site manufacturing that can be used.

Modular construction provides a viable alternative to traditional (stick building) construction in view of enabling technologies developed earlier such as that used in the shipbuilding and automotive industries. The percentage of off- site manufacturing for modular construction ranges between 60 and 70%, comparing to 30 to 50% for hybrid construction and 15 to 25% for panelized construction [1].

This accounts for 50 to 60% of construction time reduction for modular construction compared to 30 to 40% for hybrid construction and 20 to 30% for panelized construction [1].

The advantages of modular construction were identified several decades ago [2] and more recently by O'Connor et al., [3]; investigating a set of critical success factors and enablers for optimum industrial modularization. Studying the critical success factors for modularization provided an overall idea highlighting needed changes in current engineering, procurement and construction (EPC) project delivery system to support optimal use of modularization. These studies, however, did not provide a systematic process to quantify the degree of modularity in construction projects. This quantification will enable the modular construction system to compete with the hybrid construction system. Since more manufacturers are beginning to use hybrid construction to eliminate some of the dimensional limitations that modular manufacturers currently face [4].

This paper provides a novel methodology for near optimum selection of module configuration. The methodology addresses the lack of knowledge by architects about the limitations of the manufacturing process of modules, which was identified in an earlier study [5]. In fact, architects should design modules as production designers to standardize the process of module manufacturing [6].

The developed methodology is accomplished by considering a set of practical constraints and factors that affect module configuration such as onsite connections limitation, transportation and weights limitations, crane cost limitation, and the required concrete quantities for project foundation.

Section snippets

Literature review

Modularization is a concept of mass customization for products that have been successfully adapted by various industries [7]. Product configuration focuses on structuring and standardizing products models to fulfill customer needs [8]. In the construction industry, the needs of customers have been identified based on building geometrical shapes; arranged in a manner that maximizes the Quality Function Deployment (QFD) in the design phase [9], [10].

The QFD analysis requires the input of customer

Methodology

The developed methodology utilizes five indices, which accounts for connections of modules onsite (CI), transportation of fabricated modules to construction jobsite (TDI and TSDI), crane operating condition and related cost (CCPI) and project concrete foundation (CVI). These five indices are integrated into one indicator (MSI) measuring the relative suitability of competing modular designs. These indices are described below.

Case study

This hypothetical case study is presented to illustrate the use of proposed indices and to validate the proposed methodology by comparing indices values for the manufacturing two projects in three different cities (e.g. Ottawa, Quebec City, and Kingston) by three different manufacturers. Each manufacturer develops one project as design A and one project as design B as shown in Fig. 6, while this project is constructed in Montreal after comparing the three manufacturers cost penalty indices and

Discussion

Offsite construction systems are competing currently to gain more share in the market place. This creates competition against traditional stick-built construction and invites construction managers to assess and evaluate these two competing alternatives with respect to project schedule, cost, quality, and project's unique constraints such as transportation, manufacturing, and craning limitations. This evaluation requires structured tools to assist in the selection process. Critical to the

Conclusion and future work

This paper presented a newly developed methodology to support the process of identification and selection of near optimum module configurations that account for project conditions. It assists developers and project stakeholders in delivering projects not only with accelerated schedules but also with cost reduction. The developed modular suitability index (MSI) provides a quantitative indicator for the suitability of module design configurations in building construction. It integrates the effect

Acknowledgements

The authors wish to thank Dr. Hany Elsawah and Dr. Ibrahim Bakry for their comments and review of the manuscript of this paper.

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View full text

Near optimum selection of module configuration for efficient modular construction

Highlights

Abstract

Introduction

Section snippets

Literature review

Methodology

Case study

Discussion

Conclusion and future work

Acknowledgements

J. Nucl. Eng. Des.

Design in Modular Construction

Constructability Improvement Using Prefabrication, Preassembly, and Modularization

Critical success factors and enablers for optimum and maximum industrial modularization

J. Constr. Eng. Manag.

Piecing Together Modular: Understanding the Benefits and Limitations of Modular Construction Methods for Multifamily Development

A Case Study Approach to Identifying the Constraints and Barriers to Design Innovation for Modular Construction

Prefab Architecture: A Guide to Modular Design and Construction

Modular Function Deployment – A Method for Product Modularization

Product Customization

Using Quality Function Deployment (QFD) in the design phase of an apartment construction project

Customer-focused approaches to innovation in housebuilding

Constr. Manag. Econ.

Pilot study of Quality Function Deployment in construction projects

J. Constr. Eng. Manag.