Enhancing the Manufacturing Process in Light-Gauge Steel Off-Site Construction Using Semiautomation

Abstract

This study introduces a digitalized workflow for light-gauge steel off-site construction projects to reduce task duration, enhance data flow, and improve project cost assessment. With technological advancements, digitalization and building information modeling have become crucial in off-site construction to boost productivity. This research systematically integrates these technologies within the off-site construction framework, aiming to decrease manufacturing duration and enhance the accuracy of the bill of quantities for cost assessment during the manufacturing phase. The study addresses the knowledge and practice gap by presenting a comprehensive workflow tailored for light-gauge steel off-site construction projects. The study employs a design science research approach to develop the proposed workflow. The primary objectives are to assess whether a digitalized workflow can significantly reduce task duration and improve project cost assessment and to evaluate the financial feasibility of semiautomation in light-gauge steel off-site construction projects. A real modular project with 47 modules and a total gross floor area of 2,500 m2 is used to apply and evaluate the workflow. The effectiveness of the workflow is assessed by comparing task durations and bill of quantities accuracy before and after implementation. The economic feasibility is evaluated through a cost–benefit analysis referencing the case project. Three months of data postimplementation show a 66.67% reduction in task duration and a 45.39% improvement in bill of quantities accuracy. On average, the workflow resulted in a 38.11% reduction in production and assembly duration and a 10.77% improvement in measurement accuracy. The cost–benefit analysis indicates a payback period of 10 months and 26 days for the initial investment. The results are validated within the Canadian construction industry context. This paper focuses on the design and manufacturing phases, suggesting further studies should cover the installation and operation stages. This study presents a novel workflow designed to improve the efficiency of manufacturing processes in light-gauge steel off-site construction projects. By using digital tools and semiautomation techniques, the workflow significantly reduces the time needed for production and assembly, while also improving the accuracy of project cost estimates. For construction professionals, this can be expected to result in faster project completion and more precise budgeting. The workflow is tested on a real project and is found to result in a 38% reduction in production time and a 10% improvement in measurement accuracy. Moreover, the financial analysis reveals that the initial investment in this workflow could be recovered in just over 10 months, making it a cost-effective solution. This approach not only streamlines the manufacturing process but also enhances coordination among design, manufacturing, and assembly teams. By adopting this workflow, construction companies can expect to achieve higher productivity, to reduce errors, and to realize timelier project completion. The findings highlight the potential for digitalization and automation to transform traditional construction practices, making them more efficient, accurate, and cost-effective. Overall, this research provides a practical and financially viable strategy for improving manufacturing processes within the construction industry.