Comparative Time–Cost Analysis of Modular and Conventional Construction Using Primavera P6

Prefabricated volumetric modular building construction is an emerging technology in many countries used to develop the construction industry through its value-added benefits. The adoption of these novel technologies in the Sri Lankan construction industry has been relatively slow compared with other developing countries, delaying the development of the construction industry and the attainment of the added benefits of these technologies. Therefore, this study aims to identify the suitability of modular construction for the Sri Lankan construction industry via a survey and case study. A questionnaire survey was developed and distributed to assess and identify the benefits of implementing the concepts and constraints in Sri Lanka. Then, the construction cost of a proposed single-story house delivered through conventional and modular practices was compared. The survey results showed that introducing a modular concept to the industry is suitable and would benefit the Sri Lankan construction industry. Further, survey participants believed that the economic benefits brought in by modular construction are significantly more important than environmental and social benefits when selecting modular construction. The case study on a single-story affordable modular house showed a 32% reduction in total construction costs and a 36% reduction in labour costs compared to conventional house construction. Further, costs for total modular construction and labour were 32% and 36% less than those of conventional construction costs and labour costs. Moreover, a 16% reduction in embodied energy was observed when compared with conventional construction. Therefore, the modular concept could be used to construct affordable houses and will be cost-effective with the correct choice of material.

Modular construction offers several advantages, such as safe working conditions, fast construction, and high-quality end products. The project scheduling of modular construction should consider the time involved in the factory production, transportation, and erection processes of the units given limited resources (e.g., the number of modular units, available transportation, and workers) and project restrictions (e.g., the sequences of manufacturing production and on-site installation). However, current modular construction project scheduling techniques and previous academic approaches cannot deal with the overall project processes and production/on-site installation sequences simultaneously. This is one reason few mass-production multiple projects exist in the manufacturing industry. Moreover, it can lead to inappropriate project management guidelines and fail to minimize the overall project duration. This paper suggests a model for modular construction projects scheduling using a genetic algorithm. The results show that implementing both overall project processes and project requirements is an efficient way to develop a modular construction project schedule. The proposed optimization tool will help project managers allocate resources efficiently and reduce the completion time of multiple projects.

Modular construction has been reported to lead to a number of advantages when contrasted with conventional construction approaches, including time and cost savings, along with reduced environmental impacts. Given that the operations involved in modular construction take place within a controlled environment, an integral factor that impacts the productivity of works involved is the timely scheduling of the associated activities. Unlike conventional on-site construction methods, operations in modular construction take place in a sequential and linear manner, with large dependence on adequate resource allocation to specific workstations. In a bid to address the lack of mathematical optimisation methods that target the scheduling of operations in a modular factory setting, this paper proposes a novel mixed integer non-linear programming model for optimising the scheduling of modular construction activities on the shop floor of modular factories. The impact of scheduling of resources, such as overhead cranes, and the distance between stations to which activities are scheduled are factored in the proposed method. The solution approach presented for solving the scheduling problem involves the linearisation of the model to enable the use of efficient off-the-shelf solvers. A realistic case study is implemented, and an extensive computational experiment is also conducted to test the robustness and tractability of the proposed method. The performance of the model is also contrasted with a commonly adopted heuristic, with the model producing project durations reductions that are 43% less than that of the heuristic.

Modular construction is increasingly recognized as a transformative approach to addressing sustainability challenges in the construction industry. This study evaluates the environmental, economic, and operational benefits of modular construction compared to conventional building practices, with Suraksha Smart City in Vasai serving as a case study. The findings highlight that modular construction significantly reduces material waste, carbon emissions, and energy consumption while enhancing cost efficiency through precision manufacturing and resource optimization. Additionally, modular construction aligns with circular economy principles by promoting material reuse and recycling, contributing to broader sustainability goals such as the United Nations Sustainable Development Goals (SDGs). Despite its advantages, challenges such as high initial costs, transportation logistics, and standardization constraints must be addressed to facilitate its wider adoption. The study emphasizes the need for supportive policy frameworks, technological advancements, and industry collaboration to scale modular construction effectively and maximize its potential in sustainable urban development. Suraksha Smart City demonstrates how modular techniques can bridge the gap between rapid urbanization and environmental responsibility, paving the way for greener and more resilient urban infrastructure.

Recent advances in manufacturing methods, construction equipment, information technology tools, and project delivery systems have resulted in increased use of prefabrication and modularization. This research study identifies critical factors and constraints that can help designers, engineers, and constructors in selecting modular construction over the conventional “stick-built” technique for commercial building projects. The decision-making process of selecting one construction method over another is complex and based on a number of factors, some of which are site conditions, skilled labor availability, transportation conditions, organizational readiness, local codes, project schedule and budget, sustainability requirements, and design complexity. The aim of this study is to identify the most critical factors and constraints that must be considered by the decision-makers for selecting modular or stick-built construction. The study employed a mixed methods research design and was divided into three phases. In the first phase, through an in-depth literature review and interviews with six industry professionals, ninety seven decision-making factors and forty three constraints were identified. In the following phase, a questionnaire survey was conducted to determine their quantitative ratings and rakings. In the final phase, with the help of a focus group of five modular construction experts, twelve critical decision-making factors and six major constraints were shortlisted and validated. It is hoped that the findings will help the Architecture, Engineering and Construction (AEC) industry in making informed decisions about the appropriate construction method selection.

The global drive for net-zero carbon emissions has made zero-carbon buildings an essential goal, with modular construction emerging as a key strategy to achieve this. This research examines how modular construction can contribute to zero-carbon building objectives, specifically focusing on healthcare buildings. The Intensive Therapy Unit (ITU) modular building project at St George's University Hospital serves as a case study, assessing the carbon footprint across various lifecycle stages and evaluating its performance according to Building Research Establishment Environmental Assessment Method (BREEAM) standards. The study demonstrates that modular construction reduces carbon emissions through energy-efficient designs, the use of low-carbon materials, and optimized resource utilization in the production phase. Waste reduction during manufacturing, shortened assembly time, and the use of renewable energy further contribute to minimizing operational emissions. Additionally, the modular design facilitates future reuse and re-cycling of components during deconstruction. While high initial capital costs remain a challenge, the benefits of modular construction in terms of energy efficiency, sustainable material use, waste management and ecological considerations make it a promising solution. The research concludes with practical recommendations for policymakers, urban planners, and construction professionals to promote modular construction as a pathway to near-zero carbon building development.

This study seeks to explore the fundamental characteristics of modular construction, which covers the details of design and construction processes, from production through to assembly. Its objective is to evaluate essential parameters, such as project timelines and costs, associated with this construction method, in comparison with traditional construction systems. This analysis is prompted by labour shortages and the lack of affordable housing in Portugal. Modular construction prioritises the adoption of prefabricated construction systems, with potential benefits including cost and time savings, contributing to the provision of quality, economically viable, and accessible housing. This study provides valuable insights to tackle housing challenges in the Portuguese context, highlighting modular construction as a promising and sustainable alternative within the engineering domain.

A-State-Of-The-Art review on modular building connections

Integrated carbon emission estimation method for construction operation and project scheduling

Project construction activities must be analyzed from the planning stage to the execution stage so that they can be achieved optimally and achieve the best performance point. Project planning relies on a project scheduling system, of course requiring updates and modifications that show the project conditions in real time. The aims of this paper is propose a project scheduling system that can accommodate projects that have large-scale activities by proposing scheduling and risk analysis using Primavera P6 and Primavera risk analysis. A case study was conducted on the construction of an inlet separator fabrication project in Batam, Indonesia. The proposed method aims to calculate the optimal project completion time through automatic scheduling with primavera software. The method demonstrates practical value for project managers in identifying the shortest project duration and estimating the most optimal time duration for carrying out activities. In addition, using automatic scheduling can provide more complex information including successors and predecessors of activities, critical times, estimates of the overall duration of the project.

A novel advanced block assembly method with 3D printed channel systems

Risk Analysis and Control Strategies for the Assembly of Major Structure Module in AP1000 Nuclear Power Project

<p>Modular construction with precast concrete has been becoming increasingly important for years. While the advantages of conventional precast construction have already been used for decades, modular structures go one step further due to the fact that no in-situ concrete or mortar is required. One way of transferring forces is to activate surface friction by post-tensioning. While shear bearing capacity is largely dependent on static friction, flexural capacity is linked to the decompression of dry joints. Two primary fields of application are bridge structures and wind turbines. Both groups of structures are stressed by non-static loads. In order to design them fatigue-resistant, an in-depth knowledge of this discontinuity zone is required. For this reason, experimental investigations, finite element analysis and probabilistic calculations were coupled in this study. The goal is a design proposal that allows the fatigue-proof design of dry joints.</p>

Sustainability in the construction industry is a panacea that ensures balance between environmental, social and economic dimensions. Despite the recognition, the implementation of sustainable construction practices faces challenges due to persistent obstacles. It is on this premises that this paper seeks to assess the challenges confronting construction industry professionals in implementing sustainable practice on construction site with a view to develop strategies for improving their adoption and effectiveness. A quantitative research approach was adopted using self-administered structure questionnaires to collect data from experienced construction professionals registered with Green Building Council of Nigeria (GBCN). A mixture of Purposive and snowball sampling technique was employed to select professionals with requisite experience, knowledge and involvement on sustainable construction practice. Data was analysed using descriptive statistics which is relative importance index (RII), to rank the severity of various challenges. The study revealed that professionals encounter significant barriers across economic, environmental and social dimensions. Among factors identified were high initial costs, investment risks and limited awareness of life-cycle cost benefits emerged as the most severe economic challenges. Environmental barriers, including poor understanding of sustainable practices and inadequate access to sustainable materials, further constrain the implementation, social factors such as low prioritization, poor perception, and limited government support exacerbate the situation. The study concludes that overcoming these obstacles requires stronger policy frameworks, increased awareness and training, and collaborative stakeholder engagement. In addition to improvement of awareness and understanding of sustainable construction, the study recommends the need to organize seminars and conferences to educate professionals and stakeholders on the benefits and lifecycle costing on sustainable practice to enhance the effective implementation of sustainable construction practices in Nigeria.

The race to net-zero emissions and resilient infrastructure has spurred rapid innovation and demands urgent transformation in structural engineering. This review synthesizes recent advances in AI-driven design, modular construction, green materials, 3D concrete printing, and lifecycle/digital tools for sustainable structures. The author surveys state-of-the-art methods and case studies, quantifying environmental benefits and highlighting adoption barriers. In AI-based design, generative and machine-learning algorithms explore vast design spaces, yielding lighter and more efficient structures than traditional methods. Modular and prefabricated systems demonstrate dramatic schedule acceleration (e.g., a Hong Kong modular hospital built in four months) and 10–21% reductions in embodied carbon compared to conventional construction. Wood and other bio-composites (e.g., mass timber, bamboo, mycelium) are shown to sequester carbon and cut global-warming potential by >25% versus concrete materials.While advanced bio-based insulation materials offer low embodied energy. 3D concrete printing enables material and form optimization, reducing waste and formwork needs and showing lower life-cycle GHG emissions for simple structural elements. Finally, integrated life-cycle assessment (LCA) and digital twins/IoT monitoring allow real-time optimization of energy use and maintenance, further curbing carbon footprints. The author discusses cross-cutting challenges (data requirements, codes/regulations, and material durability) and proposes future directions. This comprehensive review underscores how converging technologies can reshape future skylines into greener, more efficient designs and outlines pathways for their wider implementation.