Technical Papers
Apr 26, 2023

Optimizing Modularization of Residential Housing Designs for Rapid Postdisaster Mass Production of Housing

Publication: Journal of Construction Engineering and Management
Volume 149, Issue 7

Abstract

Postdisaster housing reconstruction (PDHR) is a highly complex process because of the large number of recovery projects for affected communities and the shortage of resources after a disastrous event. PDHR also needs a strategy that reconsiders it as a large-scale integrated portfolio of projects instead of individual building reconstruction projects. However, this complexity and the lack of a holistic, systematic approach for planning frequently lead to an ad-hoc or case-by-case decision-making process. To resolve this critical challenge in postdisaster housing mass production, this study investigates and develops a systematic approach that optimizes the design modularization of housing recovery projects considering manufacturing, transportation, and assembly factors for a cost-efficient and sustainable implication of modular construction (MC) in PDHR. Using the genetic algorithm-based optimization method, the proposed method addresses the possible trade-offs between the commonality and suitability of the module configurations for PDHR projects. In addition, the authors used a set of feasible configurations of a variety of modular housing designs created from the AI-based generative design system and conducted the mass production scenarios after a disaster to validate the accuracy and robustness of the proposed methodology. The results clearly show that the proposed method significantly improved optimization and decision-making of MC design and construction processes and considerably enhanced rapid and logical responses to the demands of the postdisaster recovery process. The newly developed method is expected to assist the planners in formalizing the commonality concept in the PDHR process and achieving an optimal level of modularity and commonality that meet the required variation while maintaining the advantages of mass production.

Get full access to this article

View all available purchase options and get full access to this article.

Data Availability Statement

All data, models, or code generated or used during the study are available from the corresponding author by request.

Acknowledgments

The authors acknowledge the research support of the Louisiana Economic Development Assistantship (EDA).

References

Alfieri, E., E. Seghezzi, M. Sauchelli, G. M. Di Giuda, and G. J. A. E. Masera. 2020. “A BIM-based approach for DfMA in building construction: Framework and first results on an Italian case study.” Archit. Eng. Des. Manage. 16 (4): 247–269. https://doi.org/10.1080/17452007.2020.1726725.
Almashaqbeh, M., and K. El-Rayes. 2021. “Optimizing the modularization of floor plans in modular construction projects.” J. Build. Eng. 39 (Jul): 102316. https://doi.org/10.1016/j.jobe.2021.102316.
Banks, C., R. Kotecha, J. Curtis, C. Dee, N. Pitt, and R. Papworth. 2018. “Enhancing high-rise residential construction through design for manufacture and assembly—A UK case study.” Proc. Inst. Civ. Eng. Manage. Procure. Law 171 (4): 164–175. https://doi.org/10.1680/jmapl.17.00027.
Baylis, K., G. Zhang, and D. A. McAdams. 2018. “Product family platform selection using a Pareto front of maximum commonality and strategic modularity.” Res. Eng. Des. 29 (4): 547–563. https://doi.org/10.1007/s00163-018-0288-5.
Bolt, R., and G. Arzymanow. 1982. “Pre-assembly of the Sullom Voe process facilities.” Chem. Eng. Prog. (United States) 78 (11): 64–69.
Cao, J., D. F. Bucher, D. M. Hall, and J. Lessing. 2021. “Cross-phase product configurator for modular buildings using kit-of-parts.” Autom. Constr. 123 (Mar): 103437. https://doi.org/10.1016/j.autcon.2020.103437.
Carrillo, V. M., and H. Taboada. 2012. “A post-pareto approach for multi-objective decision making using a non-uniform weight generator method.” Procedia Comput. Sci. 12 (Jan): 116–121. https://doi.org/10.1016/j.procs.2012.09.040.
Da Rocha, C. G., C. T. Formoso, and P. Tzortzopoulos. 2015. “Adopting product modularity in house building to support mass customisation.” Sustainability 7 (5): 4919–4937. https://doi.org/10.3390/su7054919.
Da Silveira, G., D. Borenstein, and F. S. Fogliatto. 2001. “Mass customization: Literature review and research directions.” Int. J. Prod. Econ. 72 (1): 1–13. https://doi.org/10.1016/S0925-5273(00)00079-7.
Deb, K., S. Agrawal, A. Pratap, and T. Meyarivan. 2000. “A fast elitist non-dominated sorting genetic algorithm for multi-objective optimization: NSGA-II.” In Proc., Int. Conf. on Parallel Problem Solving from Nature. Berlin: Springer.
Derrac, J., S. García, D. Molina, and F. Herrera. 2011. “A practical tutorial on the use of nonparametric statistical tests as a methodology for comparing evolutionary and swarm intelligence algorithms.” Swarm Evol. Comput. 1 (1): 3–18. https://doi.org/10.1016/j.swevo.2011.02.002.
Emmatty, F. J., and S. P. Sarmah. 2012. “Modular product development through platform-based design and DFMA.” J. Eng. Des. 23 (9): 696–714. https://doi.org/10.1080/09544828.2011.653330.
Gao, S., S. P. Low, and K. Nair. 2018. “Design for manufacturing and assembly (DfMA): A preliminary study of factors influencing its adoption in Singapore.” Archit. Eng. Des. Manage. 14 (6): 440–456. https://doi.org/10.1080/17452007.2018.1502653.
Garrison, J., and A. Tweedie. 2008. Modular architecture manual. Lebanon, NJ: Kullman Buildings Corporation.
Gbadamosi, A.-Q., A.-M. Mahamadu, L. O. Oyedele, O. O. Akinade, P. Manu, L. Mahdjoubi, and C. Aigbavboa. 2019. “Offsite construction: Developing a BIM-based optimizer for assembly.” J. Cleaner Prod. 215 (Apr): 1180–1190. https://doi.org/10.1016/j.jclepro.2019.01.113.
Ghannad, P., and Y.-C. Lee. 2021. “Developing an advanced automated modular housing design system using deep learning and Building Information Modeling (BIM).” In Proc., ASCE Int. Conf. Computing in Civil Engineering (i3CE) 2021 Conf. Reston, VA: ASCE.
Ghannad, P., and Y.-C. Lee. 2022. “Automated modular housing design using a module configuration algorithm and a coupled generative adversarial network (CoGAN).” Autom. Constr. 139 (Jul): 104234. https://doi.org/10.1016/j.autcon.2022.104234.
Ghannad, P., Y.-C. Lee, and J.-O. Choi. 2020a. “Feasibility and implications of the modular construction approach for rapid post-disaster recovery.” Int. J. Industrialized Constr. 1 (1): 64–75. https://doi.org/10.29173/ijic220.
Ghannad, P., Y.-C. Lee, C. Friedland, J. Choi, and E. Yang. 2020b. “Multi-objective optimization of postdisaster reconstruction processes for ensuring long-term socioeconomic benefits.” ASCE J. Manage. Eng. 36 (4): 04020038. https://doi.org/10.1061/(ASCE)ME.1943-5479.0000799.
Ghannad, P., Y.-C. Lee, C. Friedland, and E. Yang. 2019. “Optimizing the socioeconomic benefit of postdisaster strategy by prioritizing reconstruction of damaged facilities.” In Computing in civil engineering 2019: Smart cities, sustainability, and resilience, 180–187. Reston, VA: ASCE. https://doi.org/10.1061/9780784482445.023.
Girmscheid, G., and T. Rinas. 2012. “Business design modeling for industrialization in construction: Cooperative approach.” J. Archit. Eng. 18 (2): 164–175. https://doi.org/10.1061/(ASCE)AE.1943-5568.0000089.
Goldberg, D. E., and J. H. Holland. 1988. “Genetic algorithms and machine learning.” Mach. Learn. 3 (Oct): 95–99. https://doi.org/10.1023/A:1022602019183.
Gunawardena, T., T. Ngo, P. Mendis, L. Aye, and R. Crawford. 2014. “Time-efficient post-disaster housing reconstruction with prefabricated modular structures.” Open House Int. 39 (3): 59–69. https://doi.org/10.1108/OHI-03-2014-B0007.
Halme, M., and P. Korhonen. 2000. “Restricting weights in value efficiency analysis.” Eur. J. Oper. Res. 126 (1): 175–188. https://doi.org/10.1016/S0377-2217(99)00290-8.
Hvam, L., N. H. Mortensen, and J. Riis. 2008. Product customization. Berlin: Springer.
Jansson, G., and E. Viklund. 2015. “Advancement of platform development in industrialised building.” Procedia Econ. Finance 21 (Jan): 461–468. https://doi.org/10.1016/S2212-5671(15)00200-2.
Jensen, P. 2014. “Configuration of platform architectures in construction.” Ph.D. dissertation, Dept. of Civil, Enviromental and Natural Resources Engineering, Luleå Tekniska Universitet.
Jiao, J. R., T. W. Simpson, and Z. Siddique. 2007. “Product family design and platform-based product development: A state-of-the-art review.” J. Intell. Manuf. 18 (1): 5–29. https://doi.org/10.1007/s10845-007-0003-2.
Jones, S., M. Tefe, and S. Appiah-Opoku. 2013. “Proposed framework for sustainability screening of urban transport projects in developing countries: A case study of Accra, Ghana.” Transp. Res. Part A Policy Pract. 49 (Mar): 21–34. https://doi.org/10.1016/j.tra.2013.01.003.
Karvetski, C. W., J. H. Lambert, and I. Linkov. 2009. “Emergent conditions and multiple criteria analysis in infrastructure prioritization for developing countries.” J. Multi-Criteria Decis. Anal. 16 (5–6): 125–137. https://doi.org/10.1002/mcda.444.
Khalili, A., and D. K. Chua. 2013. “IFC-based framework to move beyond individual building elements toward configuring a higher level of prefabrication.” J. Comput. Civ. Eng. 27 (3): 243–253. https://doi.org/10.1061/(ASCE)CP.1943-5487.0000203.
Kudsk, A., L. Hvam, C. Thuesen, M. O’Brien Gronvold, and M. Holo Olsen. 2013. “Modularization in the construction industry using a top-down approach.” Open Constr. Build. Technol. J. 7 (1): 88–98. https://doi.org/10.2174/1874836801307010088.
Larsson, J., W. Lu, J. Krantz, and T. Olofsson. 2016. “Discrete event simulation analysis of product and process platforms: A bridge construction case study.” J. Constr. Eng. Manage. 142 (4): 04015097. https://doi.org/10.1061/(ASCE)CO.1943-7862.0001093.
Levin, M. S. 2009. “Combinatorial optimization in system configuration design.” Autom. Remote Control 70 (3): 519–561. https://doi.org/10.1134/S0005117909030187.
Lin, P., and N. Wang. 2017. “Stochastic post-disaster functionality recovery of community building portfolios I: Modeling.” Struct. Saf. 69 (Nov): 96–105. https://doi.org/10.1016/j.strusafe.2017.05.002.
Liu, H., Y. Zhang, Z. Lei, H. X. Li, and S. Han. 2021. “Design for manufacturing and assembly: A BIM-enabled generative framework for building panelization design.” Adv. Civ. Eng. 2021 (Apr): 1–14. https://doi.org/10.1155/2021/5554551.
Liu, Z., Y. S. Wong, and K. S. Lee. 2010. “Modularity analysis and commonality design: A framework for the top-down platform and product family design.” Int. J. Prod. Res. 48 (12): 3657–3680. https://doi.org/10.1080/00207540902902598.
MacCarthy, B., P. G. Brabazon, and J. Bramham. 2003. “Fundamental modes of operation for mass customization.” Int. J. Prod. Econ. 85 (3): 289–304. https://doi.org/10.1016/S0925-5273(03)00117-8.
Malmgren, L., P. Jensen, and T. Olofsson. 2011. “Product modeling of configurable building systems: A case study.” J. Inf. Technol. Constr. 16 (41): 697–712.
Martínez, S., A. Jardón, J. G. Victores, and C. Balaguer. 2013. “Flexible field factory for construction industry.” Assembly Autom. 33 (2): 175–183. https://doi.org/10.1108/01445151311306708.
Pielke, R. A., Jr., J. Gratz, C. W. Landsea, D. Collins, M. A. Saunders, and R. Musulin. 2008. “Normalized hurricane damage in the United States: 1900–2005.” Nat. Hazard. Rev. 9 (1): 29–42. https://doi.org/10.1061/(ASCE)1527-6988(2008)9:1(29).
Piller, F. T., and C. M. Stotko. 2002. “Mass customization: Four approaches to deliver customized products and services with mass production efficiency.” In Proc., IEEE Int. Engineering Management Conf. New York: IEEE.
Pine, B. J. 1993. Mass customization. Boston: Harvard Business School Press.
Popovic, D. 2020. “The development and use of product platforms in single-family industrialized house building.” Ph.D. dissertation, School of Engineering, Jönköping Univ.
Ramaji, I. J., A. M. Memari, and J. I. Messner. 2017. “Product-oriented information delivery framework for multistory modular building projects.” J. Comput. Civ. Eng. 31 (4): 04017001. https://doi.org/10.1061/(ASCE)CP.1943-5487.0000649.
Rausch, C., M. Nahangi, M. Perreault, and C. T. Haas. 2017. “Optimum assembly planning for modular construction components.” J. Comput. Civ. Eng. 31 (1): 04016039. https://doi.org/10.1061/(ASCE)CP.1943-5487.0000605.
Said, H. M., T. Chalasani, and S. Logan. 2017. “Exterior prefabricated panelized walls platform optimization.” Autom. Constr. 76 (Apr): 1–13. https://doi.org/10.1016/j.autcon.2017.01.002.
Salama, T., A. Salah, O. Moselhi, and M. Al-Hussein. 2017. “Near optimum selection of module configuration for efficient modular construction.” Autom. Constr. 83 (Nov): 316–329. https://doi.org/10.1016/j.autcon.2017.03.008.
Schott, J. R. 1995. “Fault tolerant design using single and multicriteria genetic algorithm optimization.” Ph.D. dissertation, Dept. of Aeronautics and Astronautics, Massachusetts Institute of Technology.
Seffar, N., and C. Abbott. 2017. “The use of offsite construction method to reconstruct Iraq.” In Proc., 13th Int. Postgraduate Research Conf. 2017, 456. Manchester, UK: Univ. of Salford, School of the Built Environment.
Shahtaheri, Y., C. Rausch, J. West, C. Haas, and M. Nahangi. 2017. “Managing risk in modular construction using dimensional and geometric tolerance strategies.” Autom. Constr. 83 (Nov): 303–315. https://doi.org/10.1016/j.autcon.2017.03.011.
Sharafi, P., M. N. Hadi, and L. H. Teh. 2014. “Geometric design optimization for dynamic response problems of continuous reinforced concrete beams.” J. Comput. Civ. Eng. 28 (2): 202–209. https://doi.org/10.1061/(ASCE)CP.1943-5487.0000263.
Sharma, S., A. Sawhney, and M. Arif. 2017. “Parametric modelling for designing offsite construction.” Procedia Eng. 196 (Jan): 1114–1121. https://doi.org/10.1016/j.proeng.2017.08.069.
Smith, R. E. 2010. Prefab architecture: A guide to modular design and construction. Hoboken, NJ: Wiley.
Taboada, H. A., and D. W. Coit. 2007. “Data clustering of solutions for multiple objective system reliability optimization problems.” Qual. Technol. Quant. Manage. 4 (2): 191–210. https://doi.org/10.1080/16843703.2007.11673145.
Teribele, A., and B. Turkienicz. 2018. “Generative model and fixing guidelines for modular volumetric architecture.” Rev. Constr. 17 (3): 517–530. https://doi.org/10.7764/RDLC.17.3.517.
Thevenot, H. J., and T. W. Simpson. 2006. “Commonality indices for product family design: A detailed comparison.” J. Eng. Des. 17 (2): 99–119. https://doi.org/10.1080/09544820500275693.
Tian, Y., H. Wang, X. Zhang, and Y. Jin. 2017. “Effectiveness and efficiency of non-dominated sorting for evolutionary multi-and many-objective optimization.” Complex Intell. Syst. 3 (4): 247–263. https://doi.org/10.1007/s40747-017-0057-5.
Trevisan, L. 2004. “Inapproximability of combinatorial optimization problems.” Preprint, submitted September 24, 2004. https://arxiv.org/abs/0409043.
Ulrich, K. 1995. “The role of product architecture in the manufacturing firm.” Res. Policy 24 (3): 419–440. https://doi.org/10.1016/0048-7333(94)00775-3.
Venkat, V., S. H. Jacobson, and J. A. Stori. 2004. “A post-optimality analysis algorithm for multiobjective optimization.” Comput. Optim. Appl. 28 (3): 357–372. https://doi.org/10.1023/B:COAP.0000033968.55439.8b.
Wacker, J. G., and M. Treleven. 1986. “Component part standardization: An analysis of commonality sources and indices.” J. Oper. Manage. 6 (2): 219–244. https://doi.org/10.1016/0272-6963(86)90026-4.
Weerasinghe, P., T. Samarasinghe, T. Gunawardena, K. Nguyen, P. Mendis, T. Ngo, and L. Aye. 2018. “An optimum construction strategy for multi-story residential prefabricated modular buildings.” In Proc., ZEMCH 2018 Int. Conf. Melbourne, Australia: Melbourne School of Design, Univ. of Melbourne.
Wikberg, F., T. Olofsson, and A. Ekholm. 2014. “Design configuration with architectural objects: Linking customer requirements with system capabilities in industrialized house-building platforms.” Construct. Manage. Econ. 32 (1–2): 196–207. https://doi.org/10.1080/01446193.2013.864780.
Winch, G. 2003. “Models of manufacturing and the construction process: The genesis of re-engineering construction.” Build. Res. Inf. 31 (2): 107–118. https://doi.org/10.1080/09613210301995.
Wong, C. K., I. Fung, and C. M. Tam. 2010. “Comparison of using mixed-integer programming and genetic algorithms for construction site facility layout planning.” J. Constr. Eng. Manage. 136 (10): 1116–1128. https://doi.org/10.1061/(ASCE)CO.1943-7862.0000214.
Yuan, Z., C. Sun, and Y. Wang. 2018. “Design for manufacture and assembly-oriented parametric design of prefabricated buildings.” Autom. Constr. 88 (Apr): 13–22. https://doi.org/10.1016/j.autcon.2017.12.021.
Zhang, Q., and H. Li. 2007. “MOEA/D: A multiobjective evolutionary algorithm based on decomposition.” IEEE Trans. Evol. Comput. 11 (6): 712–731. https://doi.org/10.1109/TEVC.2007.892759.

Information & Authors

Information

Published In

Go to Journal of Construction Engineering and Management
Journal of Construction Engineering and Management
Volume 149Issue 7July 2023

History

Received: Oct 31, 2021
Accepted: Jun 16, 2022
Published online: Apr 26, 2023
Published in print: Jul 1, 2023
Discussion open until: Sep 26, 2023

Permissions

Request permissions for this article.

Authors

Affiliations

Assistant Professor, Dept. of Civil Engineering and Construction, Bradley Univ., Peoria, IL 61614. ORCID: https://orcid.org/0000-0002-5279-0548. Email: [email protected]
Leadership in Energy and Environmental Design (LEED) Acredited Professional and Assistant Professor, Bert S. Turner Dept. of Construction Management, Louisiana State Univ., Baton Rouge, LA 70803 (corresponding author). ORCID: https://orcid.org/0000-0002-0040-0894. Email: [email protected]

Metrics & Citations

Metrics

Citations

Download citation

If you have the appropriate software installed, you can download article citation data to the citation manager of your choice. Simply select your manager software from the list below and click Download.

Cited by

  • Graph-Based Evolutionary Search for Optimal Hybrid Modularization of Building Construction Projects, Journal of Construction Engineering and Management, 10.1061/JCEMD4.COENG-14687, 150, 8, (2024).

View Options

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Get Access

Access content

Please select your options to get access

Log in/Register Log in via your institution (Shibboleth)
ASCE Members: Please log in to see member pricing

Purchase

Save for later Information on ASCE Library Cards
ASCE Library Cards let you download journal articles, proceedings papers, and available book chapters across the entire ASCE Library platform. ASCE Library Cards remain active for 24 months or until all downloads are used. Note: This content will be debited as one download at time of checkout.

Terms of Use: ASCE Library Cards are for individual, personal use only. Reselling, republishing, or forwarding the materials to libraries or reading rooms is prohibited.
ASCE Library Card (5 downloads)
$105.00
Add to cart
ASCE Library Card (20 downloads)
$280.00
Add to cart
Buy Single Article
$35.00
Add to cart

Media

Figures

Other

Tables

Share

Share

Copy the content Link

Share with email

Email a colleague

Share