Industrializing the Building Construction Process

Dr. Mohamed Al-HusseinEmail: malhussein@ualberta.ca

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A Real Solution

Residential Construction Material Waste Minimization

Wood, 24%

Drywall, 11%

Cardboard, 38%

Masonry, 1%

Metals, 4%

Other, 22%

(by volume)

EMISSIONS ANALYSIS: ON-SITE CONSTRUCTION CO2 EMISSIONStage Description co2 (kg)

1 Stake Out 232 Deep Services & Foundation Walls 22573 Backfill & Shallow Trenching 9264 Capping Shallow Services 10575 Framing Main & Second Joists 4826 Framing Second & Roof 7787 Roofing 5148 Siding & Rough-Ins 3819 Electrical RI & Slabs 34410 Insulation & Boarding 56211 Drywall Taping & Texture 42012 Stage 1 Finishing & Cabinets 16713 Railing & Painting 76314 Tile & Vinyl Flooring 32615 Hardwood & Stage 2 Finishing 27016 Carpet & Finals 32617 Touch-Ups & Pre-Occupancy 311

Total 9908

0 500 1000 1500 2000 2500

1

2

3

4

5

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7

8

9

10

11

12

13

14

15

16

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23%

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CO2 Emissions from Transportation and Crew Trips

TasksDuration

(hr)Material Trips Crew Trips CO2 (kg)

Load Drywall 2 1 5t truck   46.4Drywall Boarding

32   5t picker 40.5 truck

54.4

Materialcu.yd/

1000 sq.ft.tonnes/

1000 sq.ft

Wood 6.0 0.73Gypsum 1.1 0.27Metal - -Concr./Asph. 0.04 0.05Cardboard 2.4 0.05Other 0.5 0.14

Total 10.04 1.24

Residential Low-rise

24kg of CO2 per kg of manufactured drywall1

8.64MJ/Kg of manufactured drywall2

0.76 kg CO2/sf of manufactured drywall3

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The cost of weather protection & scaffolding

Building 4-times

Replacing 7-Studnet dorms bungalows

With 5- each is 3-story in one summer

The challenge is how to assemble on site these 5 3-story each in 10-working days

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June 15

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Other level of industrialization & its

Application

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Today’s Technical Challenges

Drafting For Manufacturing (DFM)Lean Manufacturing

BIM ModelingBeyond BIM

Supporting Tools

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Industrialization creates new requirements for designCurrent Drafting software Does NOT support the

manufacturing

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ALGORITHM ANALYSIS: FRAMEX

• 3D Model

• Floor plan

45,000 + lines of Code

CUTEX: 2D-OPTIMIZATION

0

0minJj

j

0)'( mM

Tm ),,,,,( '1

11

01

23

1

23

1(%)

iii

ii

An

SW

Sheets Residual

Non-Guillotine cutting

Gilmore-Gomory

Cutting pattern

Possible cuts

Cutting pattern vector

Waste

Guillotine cutting

CUTEX: 2D-OPTIMIZATION (CON)

Waste : 2.4%

Beyond BIM: Lifting Scenario

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Scenario 1Kullman Arrangement

one building @ a time(1-Building in 2- days)

-Background Color –one day of operation-Box – module number, sequence, Advance-Present-A, B, B1 – spots for module lifting-PB1 – place building 1

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What is happening in Europe

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