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Modular Construction: A Comprehensive Review
Modular construction has the potential to transform the construction industry, as most (80–95%) of the modules, which are considered prefabricated buildings, are manufactured off-site, which is more efficient, safe, cost-effective, sustainable, productive, and faster than traditional construction. It is not without challenges, however, as it requires detailed and comprehensive planning, high initial costs, and navigating transportation and design constraints. The goal of this study was to identify and categorize the benefits and challenges of modular construction and offer strategies for resolving the challenges. This study also provides a comprehensive review of modular construction methods, including permanent modular construction (PMC), movable modular construction (RMC), volumetric modular construction (VMC), and panelized construction, and examines the connectivity of the modules, as well as the integration of advanced technologies like artificial intelligence (AI). The results revealed that the most frequently cited benefits of modular construction were reducing construction time by up to 50%, 20% cost savings, and material waste reduction of up to 83%. The most common challenges included transportation complexity, limited design flexibility, and high initial costs. The results of this study will assist project managers, construction professionals, and company owners in evaluating modular construction by providing quantified benefits and challenges, a comparative analysis of different modular methods, and insights into effective mitigation strategies, allowing them to assess its suitability based on project timelines, budgets, design requirements, and logistical constraints.
Journal Article
Prefab housing and the future of building : product to process
As we stand on the cusp of a fundamental restructuring of the housing and building industries, this book provides a timely overview of prefabricated and modular housing. The idea of prefabricated and modular housing is not a new one: since the 19th century, designers, inventors, engineers, builders, developers, and entrepreneurs have all been fascinated by the idea of the factory-built home. But the current international housing shortages and affordability crises have given a new urgency to the need to transform building construction in the 21st century. Richly illustrated and drawing on historical examples and contemporary design studies, the book takes the reader through the history, theory and design of the prefab, leading up to a discussion of contemporary problems and opportunities.
Book
Barriers to modular construction systems implementation in developing countries’ architecture, engineering and construction industry
PurposeThis study aimed to identify and assess the barriers to implementing modular construction systems (MCS) in developing country's architecture, engineering and construction (AEC) industry, targeting built environment professionals from Nigeria and South Africa.Design/methodology/approachThe study adopted a quantitative research method, using a structured questionnaire to seek the opinions of the professionals on the identified categories of barriers.FindingsResults indicated that all identified categories of barriers were statistically significant using a one-sample t-test at p = 0.05 significance level which indicates they are critical towards the implementation of MCS in developing countries. Assessment of the opinion of the professionals using the Kruskal–Wallis scale showed that they hold similar views on the barriers to the adoption of MCS. Pearson correlation shows a high correlation coefficient amongst the barrier categories and an acceptable level of significance (p = 0.05).Research limitations/implicationsThis study is limited to two significant African countries (Nigeria and South Africa) selected based on the gross domestic product (GDP). Further studies can consider developing countries outside Africa and investigate broader respondents.Practical implicationsThe study provides implications on the barriers affecting MCS in developing countries for the academia, industry and government to have an insight into the barriers and make informed decisions and policies.Originality/valueThe research satisfies the need to study the barriers affecting the MCS in developing countries that can mitigate housing deficits. This innovative construction method has been adopted and implemented in developed countries, and the result has been positive.
Journal Article
Minimizing transportation cost of prefabricated modules in modular construction projects
PurposeThe objective of this research study is to formulate and develop a novel optimization model that enables planners of modular construction to minimize the total transportation and storage costs of prefabricated modules in modular construction projects.Design/methodology/approachThe model is developed by identifying relevant decision variables, formulating an objective function capable of minimizing the total transportation and storage costs and modelling relevant constraints. The model is implemented by providing all relevant planner-specified data and performing the model optimization computations using mixed-integer programming to generate the optimal solution.FindingsA case study of hybrid modular construction of a healthcare facility is used to evaluate the model performance and demonstrate its capabilities in minimizing the total transportation and onsite storage costs of building prefabricated modules.Research limitations/implicationsThe model can be most effective in optimizing transportation for prefabricated modules with rectangular shapes and might be less effective for modules with irregular shapes. Further research is needed to consider the shape of onsite storage area and its module arrangement.Practical implicationsThe developed model supports construction planners in improving the cost effectiveness of modular construction projects by optimizing the transportation of prefabricated modules from factories to construction sites.Originality/valueThe original contributions of this research is selecting an optimal module truck assignment from a feasible set of trucks, identifying an optimal delivery day of each module as well as its location and orientation on the assigned truck and complying with relevant constraints including the non-overlap of modules on each truck, shipment weight distribution and aerodynamic drag reduction.
Journal Article
Volumetric Modular Construction Risks: A Comprehensive Review and Digital-Technology-Coupled Circular Mitigation Strategies
Volumetric modular construction (VMC) has considerable benefits in providing better cost, time, quality, productivity, and sustainability performance. However, the adoption is low, owing to various associated risks. This study aims to identify VMC critical risk factors (CRFs) in project stages and project attributes by conducting a systematic literature review of 91 articles. In the project stages, 31 CRFs were identified based on frequency analyses, and divided into four stages: design and planning, offsite manufacturing, transportation and logistics, and onsite assembly. The project attribute risks were divided into the following categories: implementation and schedule, supply chain and financial, safety and ergonomic, and civil and structural. Overall, design and planning risks were critical, as they are crucial in maintaining the project’s upstream and downstream flow. Finally, the study proposed a mitigation framework for using digital technology-based circular strategies to overcome VMC risks. The framework includes disruptive and emergent digital technologies aiming to mitigate risks in VMC, keeping circularity in action. In terms of theoretical contributions, this research delivers a CRF register and categorical division for professionals to better understand the landscape of VMC risks. In terms of practical contributions, the study guides the practitioners towards strategies to overcome the pertinent risks.
Journal Article
Design and Implementation of Quality Information Management System for Modular Construction Factory
Modular construction has been gaining increasing attention from industry and academia as a solution to the limitations of the traditional on-site orient production systems in the construction industry. Various attempts have been made to improve modular construction performance. However, while previous studies have attempted to enhance the productivity of modular construction, attempts to improve the efficiency of quality management in modular construction have been limited. Moreover, the quality management practices in a modular factory still rely on document-oriented quality information management, which is inefficient. Therefore, this study aims to develop a quality information management system to improve quality information management during module manufacturing. Accordingly, quality information during module manufacturing has been standardized using integration definition for process modeling, and system functions are defined using standardized quality information. The developed modular factory quality information management system includes module information and production-type management, material management, and module production management. The practicability and validity of the developed system were examined by accredited tests and certification laboratory and modular construction experts. The developed system is expected to contribute to improving the existing inefficient quality management process of module manufacturers by providing an integrated and systematic method to manage quality information generated during manufacturing.
Journal Article
Developing a systematic performance measurement framework for benchmarking steel modular building construction
PurposeModular construction is an innovative method that enhances the performance of building construction projects. However, the performance of steel modular construction has not been systematically understood, and the existing measurement methods exhibit limitations in effectively addressing the features of steel modular building construction. Therefore, this study aims to develop a new performance measurement framework for systematically examining the performance of steel modular construction in building projects.Design/methodology/approachThis study was conducted through a mixed-method research design that combines a comprehensive review of the state-of-the-art practices of construction performance measurement and a case study with a 17-story steel modular apartment building project in Hong Kong. The case project was measured with data collected from the project teams and other reliable channels, and the measurement practices and findings were referenced to establish a systematic performance measurement framework for steel modular construction.FindingsConsidering steel modular construction as a complex socio-technical system, a systematic performance measurement framework was developed, which considers the features of steel modular construction, focuses on the construction stage, incorporates the views of various stakeholders, integrates generic and specific key performance indicators and provides a benchmarking process. Multifaceted benefits of adopting steel modular construction were demonstrated with case study, including improved economic efficiency (e.g. nearly 10% cost savings), improved environmental friendliness (e.g. approximately 90% waste reduction) and enhanced social welfare (e.g. over 60% delivery trips reduction).Originality/valueThis paper extends the existing performance measurement methods with a new framework proposed and offers experience for future steel modular construction. The measured performance of the case project also contributes in-depth understanding on steel modular construction with benefits demonstrated. The study is expected to accelerate an effective uptake of steel modular construction in building projects.
Journal Article
A Review of Inter-Modular Connections for Volumetric Cross-Laminated Timber Modular Buildings
The application of volumetric modular construction using Cross-Laminated Timber (CLT) has emerged as a sustainable and efficient alternative to traditional building methods, especially in residential and mid-rise structures. However, the widespread adoption of this technology remains limited due to the lack of standardized inter-modular connection systems. This paper presents a comprehensive state-of-the-art review of inter-modular connections used in volumetric CLT modular buildings. This review aims to evaluate the inter-modular connections by developing performance objectives and identifying gaps in knowledge of volumetric CLT inter-modular connections. It begins with an overview of global CLT modular construction trends, highlighting geographic distribution, structural demands, and environmental hazards such as seismic and wind exposure. Seven representative connection systems were identified from the literature and assessed using a multi-criteria framework comprising structural performance, manufacturing feasibility, on-site construction efficiency, and experimental and numerical evaluation. Each connection was scored according to defined evaluation metrics, and the results were provided to identify key strengths and limitations. The top-performing systems demonstrated superior resilience, modular adaptability, and validation through experimental testing and simulation. The paper identified critical research gaps, including limited performance data available for seismic applications, challenges in disassembly and reuse specifications, and the need for adaptable, damage-tolerant systems to enhance building structural performance. These findings provide a reference evaluation methodology for future development of inter-modular connections, to expand the applicability of volumetric CLT modular construction in moderate and high seismic and wind hazard regions.
Journal Article
Analysis of risks arising at the stages of production, transportation, installation of large-sized modules in the design position
The paper considers the prospects for the development of large-sized modular housing construction in the face of industrial and managerial risks. The authors consider the risks identified at the time of production of a large-sized module, transportation and installation in the design position. The risk planning management algorithm is considered. The article identifies the factors that arise at the stage of production, transportation, installation of a large-sized module in the design position. A literary analysis was carried out on the topic of large-sized volume-block housing construction. The technical and economic prerequisites for the construction of buildings from large-sized modules and obtaining an economic effect are considered, in comparison with the construction of similar buildings in a large-panel or monolithic design. An algorithm for studying potentially significant factors is considered. Practical experiments were carried out, which made it possible to determine the risks affecting the quality of large-sized modules. The task of this work is to identify risks that affect the quality of large-sized modules at various stages: production, transportation, installation of a large-sized module in the design position. As a result, risks were identified by three groups for further qualitative and quantitative analysis, response planning, monitoring, and risk management. The relevance of the considered topic lies in the implementation of investment projects, in their implementation in the field of management.
Journal Article