Integrated prefabrication configuration and component grouping for resource optimization of precast production

Abstract

It may be possible to reduce uncertainty in construction projects by adopting the prefabrication method. In this method, components are produced in factories and transported to the construction site to satisfy installation demands. For successful and effective prefabrication, the project designer and precaster must develop an integrated plan to manage the available resources in a way that satisfies design flexibility, production constraints, and installation demands. Configuring individual building elements and forming building components or modular units will result in employing a higher degree of prefabrication for higher productivity and ease of construction. The production of such complex configurations requires complex molds. To achieve optimization of resources and costs for the precast production of complex configurations, two new ideas have been adopted: namely prefabrication configuration and component groups; these are incorporated into the mixed integer linear programming (MILP) model. Moreover, an integrated plan is developed to efficiently utilize complex molds in production platform by using a mold adaptability matrix. Based on these concepts, an MILP optimization model is developed to adopt appropriate molds and create an optimal production plan. The model is validated by using two examples with different scenarios. The results show that employing the idea of prefabrication configuration and component grouping in production planning for prefabricated structures can reduce total costs by up to 13% compared to the existing planning approach. The developed model should help prefabrication manufacturers better manage their resources and possibly expand their production capacity. © 2013 American Society of Civil Engineers.