virtual construction automation for modular …

VIRTUAL CONSTRUCTION AUTOMATION FOR MODULAR ASSEMBLY OPERATIONS

Jacek Olearczyk1, Mohamed Al-Hussein2, Ahmed Bouferguene3, Avi Telyas4

ABSTRACT On large construction sites crane positions tend to be determined through a process of trial and error. The analysis of complicated spatial static equipment locations is not an easy task. It requires understanding of many complicated aspects of not only the lift procedures or crane equipment limitation but also knowledge of the lifted objects. The virtual, an three-dimensional (3D) CAD modeling process allow for the storage, not only of shape and color (visual aspect), but also material properties, and parametric dependency (intelligent aspect). The utilization of advanced CAD tools allows for the exploration of the behavior of a structure. Digitally animated and simulated, modular construction assembly operation illustrate benefits of implementing 3D and 4D modeling for analysis of lifts and sequence optimization. This paper provides an example of development and methodology to optimize crane selection operation process for the onsite erection of five, three stories dormitory buildings in McGregor Village for Muhlenberg College in Allentown, Pennsylvania USA. Fully habitually modular assembly units were delivered securely on flatbed trailers in advance to the site. A 600 Tone mobile hydraulic crane was placed in the center of construction site to lift over 100 modules in order to construct the 5 buildings in only 10 working days. Created CAD models were efficiently utilized to optimize detailed schedule. The process includes the creation of kinematic movement for each module lift then simulation sequences and finally compile AVI video movie for review and approval.

1 Ph.D. Candidate, Civil and Environmental Engineering Department, Hole School of Construction 1-047 Markin/CNRL Natural Resources Engineering Facility Edmonton, AB T6G 2W2, Phone +1 780/492-8093, FAX 780/492-0249, [email protected], 2 Associate Professor, Civil and Environmental Engineering Department, Hole School of Construction 3-011 Markin/ CNRL Natural Resources Engineering Facility Edmonton, AB T6G 2W2, Phone +1 780/492-0599, FAX 780/492-0249, [email protected], 3 Associate Professor, Campus Saint-Jean 8406, Marie-Anne-Gaboury Street (91 Street) Edmonton, AB T6C 4G9, Phone +1 780/465-8719, FAX 780/465-8760, [email protected] 4 Kullman Building Corp., One Kullman Corporate Campus, Lebanon, New Jersey 08833, Phone +1 908/236-0220, Fax +1 908/236-8596;[email protected]

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Copyright ASCE 2009 2009 Construction Research Congress Construction Research Congress 2009

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INTRODUCTION Modular – or manufactured – housing is well known in the construction industry. The primary advantages to this approach are cost and completion time. If properly designed and constructed, modular housing can be developed for the fraction of the cost of traditional housing and still meet the highest quality standards. Once the completed product is transported to the place, the setup can be completed in a matter of days. However, modular construction term is associated with single housing; some authors refer it to at the most low-rise multi-family housing [Murdock 2005]. Effort to automating the model development process or using robotics in modular construction to reduce on site labor has been reported in the later return [Nasereddin et al. 2007, Bock 2007, Editorial Ca - Leonard 2007]. Also, the challenge related to a large number of modular units needed for international events is addressed [Yoders 2005]. But the most significant niche for implementing this type of building is for school facilities, campus/dormitory living, and affordable housing [Dolan 2006, Cardenas and Domenech 2005, Atkinson et al. 2001]. Some reported cases demonstrated a shift from traditional thinking of modular construction, which was focusing only on low-rise accommodations to be considered for high-rise facilities [Cartz and Crosby 2007]. Other examples of successful implementation of the modular concept includes the construction of airport roofs; NASA spacecraft architecture; and health care units, from single check-up rooms to operating theatres or pharmacy centers [Veale and Postawa 2007, Smith 2006, Editorial Health 2007, Editorial Hospital 2007, Editorial Operating 2007, Editorial Pharmacy 2008]. These facilities or units can be customized over the internet similar to the manner in which an automobile may be customized by the purchaser [Booth 2007]. Ready modules are delivered to the site for assembly, and in this respect a heuristic algorithm for optimization assembly operation can be well utilized [Da Cunha et al. 2007]. Furthermore, unskilled labor issues as well as the effect on the reduction of electricity consumption of using modular technology and the benefits of off-site construction have garnered the attention of scholars [Rehfeld 2006, Riley 2007, Editorial Off-Site 2006]. When complicated mechanical components or multi-dimension construction site movement are involved, transforming the intellectual ideas into drawings is not an easy task. Two-dimensional or isometric hand sketches on the paper are the fist media to receive human brain idea output. Often, these sketches are the only surviving evidence of new and evolutionary development. They are not recorded any other way. Today technology makes this intellectual property transparent, either allow scan or convert to digital configuration of solid modeling, and then virtually transform creating simulation or animations. Analyzing and testing cranes in 3D has a proven record of success in assisting the construction industry or analysis assembly and complicated movement using tilt-up panel construction method [Al-Hussein et al. 2005, Manrique et al. 2007]. Closing the gap between simulation and visualization and address visualization of the design constraints are the other examples of virtual technology assistance [Xu 2001, Olearczyk and Al-Hussein 2006]. Communication as an important way of exchange information and solve the problem is a key factor not only on construction site. To better understand concept of design, schedule and allocation resources over

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construction time virtual reality (VR) tool plays significant role. This dynamic graphical depiction is able to shows the proposed design just as the final product would appear in the real world. It provides visual inside information of modeled construction operation as well as helps realistically identify the proposed design [Messner et al. 2006, Okyere 2004]. VR as educational tool creates its path in academic curriculum fast and with purpose [Otto et al. 2005]. However, it is present in the industry over the past two decades and offer visualization in several level of details, does not mean limitation and constraints is not recognized [Staub-French and Khanzode 2007]. Interdisciplinary recognition of value, which VR can offer, shows utilization this technology beyond pioneers, automotive and aerospace industry, and encompasses specialized fields of human brain research, such as psychotherapy and psychology [Ehrsson 2007, Lenggenhager et al. 2007]. METHODOLOGY Figure 1 shows the main process of the proposed methodology. “Construction process” block set of operation cannot function without meaningful input parameters, which include objects, crane and rigging data strictly related to equipment information. Example of crane data includes dimensions, radii, and lifting capacities related to boom length at specific radii. These crane configurations are placed and temporary relocated on the construction site in the computer model and consequently site data has to be included as input parameter. CONSTRUCTION PROCESS

Objects data

Crane data

Rigging data

Site data

Prepare detail schedule

Perform specific part or assembly analysis

(optional)

Check interference

Collect Data“know-how” knowledge, technology, material

Build parametric CAD models

Identify liftconfiguration

Create CAD assemblies

Optimization analysis

Objects limitation

Sites limitation

Resources

Procurement method

Safety

Weather condition

Transport limitation

Schedules Simulations Kinematics analysis

INPUT CRITERIA

OUTPUT

As-Built & IFC drawingsSite Layouts

Build kinematics simulations and animations

Figure 1; Methodology flow chart

The main process, “Construction Process”, contains sub-functions blocks operations related to different tasks such as “Collect Data” which refers to exclusive knowledge, technology or materials. In the next step particular crane configuration is established and detailed schedule prepared. Based on presented information parametric CAD models are created, which further, forms the sub-assemblies or assemblies. The first

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check operation which is performed at “Construction Process” module is interference check, this operation is critical since assembled modules cannot perform uninterrupted kinematics simulation and then animation tasks. Some processes at the certain steps required optimization algorithm to be run to optimize movement, initial start position in order to reduce operation time and cost. Operations performed under “Construction Process” umbrella are subject to several criteria listed in the “Criteria” module. This module contains object, transportation and sites limitations, resources availability and functionality of procurement method used, as well as safety concerns and weather condition effect on the construction process. Separate module reflects on received output, which could be collected at any stage of the construction process operation. “Output” contains electronic schedules, simulation, and kinematics or stress analysis reports and also could be presented as hard printed copy. PROBLEM DEFINITION – CASE STUDY Rectangular modules, sized to fit standard flatbed truck trailers, were manufactured at Kullman shop in Lebanon, New Jersey and delivered to the Muhlenberg College in Allentown, Pennsylvania for assembly into five new buildings. Over ninety units placed together into five different locations like a puzzle, to create three-storey dormitory buildings, which were to house 145 students. The five new buildings replaced seven single-level “shelters” built in 1981 to accommodate only 56 pupils. Figure 2 shows exploded view of one dormitory building.

Figure 2; Dormitory exploded view Figure 3; Typical floor layout

Figure 3 shows typical floor layout with spacious rooms for its occupants. Time factor was the main construction contract constraint. The 5-buildings must be built during summer months only. Traditional stick-building construction method was eliminated since this technique required much longer on-site construction time. Manufacturing the units ahead of time, during the school time, at the factory floor assembly (module construction), allow assembling the 5-buildings on site in three weeks. Planning in advance all procedures related to fabrication, transportation, and final assembly operation would not be possible without detailed schedule and logistic preparation. Detailed flow chart (see Figure 4) was created of final assembly for all

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dorms and fine schedule (in minutes-by-minutes) of each lift and assisting operation was created (see Figure 5).

Figure 4: Building operation flow chart Figure 5: Daily schedule (minute-by-

minute)

In Figure 4 vertical columns of rectangular boxes representing delivered modules coded to shows the pick points areas B1, A and D; the solid line divide modules on to two separate days of lift operations. Module identification name and coding schema was unique to the project and followed: first number was related to one of five buildings, second floor and third floor module number, after dash number represents sequence of assembly, suffix letter A and P represents morning and afternoon operation respectively. Accordingly, one building was assembled in two days where in the second day; the last lift operation was to cover the building with the preassembled roof. Figure 5 shows spreadsheet schedule of operation with “p, ml, o” values representing pessimistic, most-likely and optimistic data respectively, for triangular distribution input analysis simulation. Accumulated data allowed optimize each assembly operation, and then create project Gant Chart schedule (see Figure 6). Detailed schedule was created independently for each assembly day. On the schedule, prior field operation, critical path was identified and tasks involved in critical path procedures were carefully planned and checked. Utilizing crane selection algorithm (Al-Hussein 2005) Demag AC 500-1 mobile hydraulic telescopic crane was chosen to perform this assignment. With a lifting capacity of 600 tons (500,000 kg) allowed to place the units in the positions optimized by Center-of-Gravity moment effect algorithm (CoG). However, crane was operating with maximum boom length of 183 feet, defined assembly sequence made critical the last lift operation (the roof of the 5th building). Boom crane came to close

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proximity of already placed building 4 and detailed clearance analysis had to be performed.

Figure 6: Day detail schedule planned vs. actual

During the entire assembly only two rigging equipment configuration were used; direct 10 feet steel cables for small modules and 50 foot long spreader bar for roofs and large modules. VIRTUAL CONSTRUCTION Analysis of complicated spatial static equipment locations is not an easy task. It requires understanding of many complicated aspects of lifting procedures, and crane and equipment limitation. To practitioners with limited experience the virtual, 3D-CAD modeling process allows for the storage, shapes and colors (visual aspect), and material properties, and parametric dependency (intelligent aspect). After optimization of the crane location and securing pick points for delivered modules, simulation optimization was performed on Simphony software (AbouRizk 2000); in order to provide the modules lifting sequences, resources allocation and timing operations of the assembly schedule. Project assembly operation was ready for CAD modeling and virtual validation. Intelligent digital objects have been assigned proper material properties and texture mapping for visualization effect. In two occasions, separate detail crane site access analysis was performed to accommodate road width limits and allowable crane boom clearance. Assigning kinematic movement to each major crane components and lift for each motion to time frame allows executing full real-like digital movies. Concatenation sets of separate hoist, swing, placing and returning operations permit to create optical illusion of 4D construction operation. Figure 7 shows a snapshot of full length digital construction movie of one building.

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Figure7: Snapshot of construction movie

Placing each module at defined time frame, gives the ability to recognize potential bottlenecks ahead of actual construction. In addition, since the 3-D model was front-loaded with resources assignment, the 4-D model relocated and utilizes resources as well. Other advantage of running animation several times, especially in presents of the rigging crew, created mental pictures of planned activities and prepared the crew to actually learn-from-movie lesson. Construction projects are unique and assembly crews learning from the already performed tasks increasingly improve their productivity. In case of Muhlenberg College project, the rigging crew productivity was close to optimal at the beginning of assembly project due to the short learning-curve time. Last lift of the project (critical lift), placing the roof for building 5 was virtually tested at many different options. Its complexity describes the fact that the crane boom was

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in conflict with already erected unit and was out of the operator view. Performing virtual analysis allow reconfigure the crane boom (add extension) and avoid problem during physical lift. Figure 8 shows collision the crane boom with building roof before reconfiguration and Figure 9 view after extension was added.

Figure 8: Collision detection Figure 8: Extension added

CONCLUSIONS The preparation aspect of the project and construction operations virtual implementation steps were covered in this paper. Economic benefit was undisputable, shortening preliminary schedule from 21 days to 10 days without sacrificing safety and quality created psychological “win” approach for all crew members. Adopted new technologies for crane layout optimization, introducing “minute-per-minute” construction schedule operation are few of many grounds-braking improvement tactics used in this project. Virtual interpretation of assembly operations has its own chapter in this state-of-art project management undertaking. In many cases decision makers do not see tangible benefits of creating CAD models for only assembly operations, usually models utilized at this final stage of procurement are outputs from design and manufacturing processes. For Muhlenberg College project modeling was done only for assembly operation, modules design and fabrication assistance was already established and it proved to be worth investment even for final steps of entire project scope. Virtual preparation is not easy task and required combination of working knowledge of CAD software with its separate module of kinematics, simulation and animation as well as understanding of “know-how” of any construction operations that has to be digitally prepared. Critical aspects of any optimization analysis are proper and valid interpretations of result and outputs. Provided case study was used to demonstrate effectiveness of the developed methodology in avoiding accidents, reducing the time and cost associated with planning and execution of lifts on construction site. As an additional benefit of virtual implementation of construction assembly operation was a data, which effectively enhance marketing communication with potential clientele.

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virtual construction automation for modular …

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