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Journal of Cleaner Production 183 (2018) 183e193

Contents lists available at ScienceDirect

Journal of Cleaner Production


journal homepage: www.elsevier.com/locate/jclepro

Key constraints and mitigation strategies for prefabricated prefinished


volumetric construction
Bon-Gang Hwang a, Ming Shan b, *, Kit-Ying Looi c
a
Department of Building, National University of Singapore, 4 Architecture Drive, 117566, Singapore
b
School of Civil Engineering, Central South University, 68 South Shaoshan Road, Changsha, 410075, China
c
Quantity Surveyor, Arcadis Singapore Pte. Ltd., 1 Magazine Road, #05e01 Central Mall, 059567, Singapore

a r t i c l e i n f o a b s t r a c t

Article history: Prefabricated prefinished volumetric construction (PPVC) is an innovative and cleaner approach that has
Received 3 October 2017 restructured the production of the construction industry. It can improve the workflow continuity, in-
Received in revised form crease the efficiencies in the use of resources, minimize construction wastes, and reduce the number of
30 January 2018
on-site contractors as well as construction durations. While the benefits of PPVC have been widely
Accepted 13 February 2018
Available online 14 February 2018
recognized over past two decades, the constraints on using PPVC remains unexplored. As a result, the
aims of this study are to investigate the significant constraints demotivating the adoption of PPVC and to
propose a group of feasible mitigation strategies to tackle these constraints. To achieve these goals, a
Keywords:
Prefabricated prefinished volumetric
comprehensive literature review was conducted first, followed by a structured questionnaire survey
construction administered to 41 Singapore-based construction organizations. Lastly, an in-depth case study was
Prefabrication conducted to verify the empirical findings. The analysis results showed that the top five significant
Off-site construction constraints were “extensive coordination required prior to and during construction”, “need for additional
Constraints project planning and design efforts”, “increased transportation and logistics considerations”, “require-
Mitigation strategies ment for early commitment”, and “higher initial cost than conventional construction method.” It also
Singapore revealed the top three most effective mitigation strategies: “encouraging close collaborations between
project stakeholders during the early phase of the project”, “use of BIM to improve coordination and
facilitate communication among project stakeholders”, and “offering training courses for project team
and workers to enhance their knowledge and skills”. This study contributes to the body of knowledge by
examining the constraints and mitigation strategies for the adoption of PPVC. Also, the findings from this
study are informative to the industry practitioners to have a better understanding and implementation of
PPVC.
© 2018 Elsevier Ltd. All rights reserved.

1. Introduction numerous benefits, off-site construction has been highly recog-


nized by the global construction community and widely used by
Off-site construction is a process that manufactures and as- the construciton industries in many countries and regions, such as
sembles building elements, components, and modules in off-site Hong Kong (Chiang et al., 2006), Spain (Pons and Wadel, 2011),
factories and then transports them to site for installation Australia (Mostafa and Chileshe, 2017), Singapore (Wu and Low,
(Goodier and Gibb, 2007; Pan and Goodier, 2012). It is a cleaner and 2012), the United Kingdom (Taylor, 2010), and the United States
innovative construction approach that can improve workflow (O'Connor et al., 2014; Song et al., 2005).
continuity and productivity (Li et al., 2016b; Mao et al., 2016), According to the degree of the off-site work undertaken for
minimize construction wastes (Arashpour et al., 2016), reduce the product, off-site construction methods can be divided at different
number of on-site trade contractors (Jaillon and Poon, 2008), and levels including component and subassembly, non-volumetric
reduce construciton durations (Arashpour et al., 2015). With its preassembly, volumetric preassembly, and modular construction
(Gibb, 1999; Pan and Goodier, 2012). Among these various methods,
prefabricated prefinished volumetric construction (PPVC) is a
* Corresponding author. typical and efficient one. In PPVC projects, modules complete with
E-mail addresses: bdghbg@nus.edu.sg (B.-G. Hwang), bdgshanming@163.com finishes for walls, floors, and ceilings are built and manufactured in
(M. Shan), looi.kitying@arcadis.com (K.-Y. Looi).

https://doi.org/10.1016/j.jclepro.2018.02.136
0959-6526/© 2018 Elsevier Ltd. All rights reserved.
184 B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193

off-site factories (mostly 85e90 percent of the project work) and of construction projects successfully (Mills et al., 2015). Although
then transported to construction site for installation (Arif and Egbu, PPVC receives some criticisms that its overuse will make buildings
2010; Kamali and Hewage, 2017; Mao et al., 2016). This method is lose aesthetic values in terms of individuality, uniqueness, and
particularly suitable for the built structures with repetitive design personality (The Business Times, 2016), its advantages are
features, such as hotels, apartments, student residence, hospitals, predominant and make itself a revolutionary method benefiting
and prisons (Mao et al., 2016). PPVC has multiple advantages. the construction industry (Lim, 2016a).
Unlike conventional construction methods where works are Recently, PPVC has become popular worldwide. In the US, a
executed in a consecutive manner, PPVC allows works to proceed growing number of colleges and universities are using PPVC to
concurrently, which can shorten of the construction schedule build quick and convenient dormitories and classrooms. As
significantly. Meanwhile, as PPVC allows the modules to be estimated by Gregor (2008), PPVC can save the colleges and
manufactured in off-site factories, it can also provide the workers universities five to ten percent of construction costs and speed up
with a pleasant working environment (Mao et al., 2015; Pan et al., the construction process at the same time. In Australia, there has
2007, 2012). been a growing trend that hotels are built using PPVC. This is
Being a city-state with limited natural resources and labor because PPVC can ensure the construction of the hotels on
supply (Gao and Low, 2014), Singapore spares no effort in chasing schedule, and meanwhile the cheap construction costs allow hotels
productivity in its various industries, particularly in the local to offer their guests a high end hotel experience at a more afford-
construction industry which is highly labor intensive (Ling et al., able rate, enhancing their competitiveness (Waters, 2017). In the
2013; Pang and Lim, 2015). Currently, the Building and Construc- UK, an increasing number of homebuilders have launched prefab
tion Authority (BCA) of Singapore is exploring every viable home divisions to build PPVC homes which are complete with light
alternative to enhance construction productivity, which includes fittings, bathrooms, bookshelves and kitchens. Also, these home-
PPVC (Lim, 2016b; Ministry of National Development (2016)). In the builders recognize PPVC a good strategy to tackle the challenge in
view of BCA, PPVC is a game-changing technology catering to the labor, namely a shortage of skilled construction workers caused by
prevailing concept of Design for Manufacturing and Assembly, and an ageing workforce and an exodus due to Brexit (Booth, 2017).
also a revolutionary construction method able to achieve a signif- Furthermore, PPVC homes are becoming increasingly common in
icant productivity improvement. As such, in 2014, PPVC became Japanese urban areas, due to improvements in design and quality,
selectively mandatory for built structures that are developed on the speed and compactness of onsite assembly, as well as due to
land released by the government, according to the regulations lowering costs and ease of repair after earthquakes (Zhang, 2015).
issued by BCA (BCA, 2017b).
Although it has been widely accepted by the global construction 2.2. PPVC in Singapore
community, so far, PPVC is still in its infancy. Much of the knowl-
edge regarding PPVC remains unexplored. As a result, this study Since 2010, BCA of Singapore has launched two rounds of
aims to explore the significant constraints that limit the adoption of Construction Productivity Roadmap (1st in 2010 and 2nd in 2015)
PPVC in existing building and construciton projects and to propose aiming to improve the productivity in local construction industry
a group of mitigation strategies that can help address these (Navaratnarajah, 2016). Particularly, in the 2nd Construction
constraints. Although there has been considerable research on Productivity Roadmap BCA highlighted that prefabrication would
offsite construction currently (e.g., Arashpour et al., 2016; Arif and be one of the main directions that the local construction industry
Egbu, 2010; Goodier and Gibb, 2007; Johnsson and Meiling, 2009; should go forward (Lim, 2016a). Recently, BCA has been promoting
Mao et al., 2015; Taylor, 2010), few of them looked into PPVC. PPVC actively. For example, BCA stipulated that the adoption of
Thus, this study can contribute to the body of knowledge of offsite PPVC method was one of the land sale conditions for some selected
construction research, especially focusing on PPVC. Meanwhile, as land parcels sold under the Government Land Sales Program from 1
this study summarized the lessons and experiences learned from November 2014 (BCA, 2017b). Subsequently, in 2015 BCA further
the real-life PPVC projects, it is also useful and informative to the stipulated that for the developments of these selected land parcels,
industry practitioners who plan to adopt PPVC method, thereby the minimum level of use of PPVC should be 65 percent of the total
benefiting their practices. constructed floor area (including all floors except the basement and
any floor area built for use as a roof or car park) (BCA, 2015).
2. Background Moreover, BCA has set up an acceptance framework to certify each
PPVC supplier and manufacturer to make sure the different PPVC
2.1. Prefabricated prefinished volumetric construction systems used at mandated development sites are reliable and
durable, (BCA, 2017b). In addition to BCA, the Housing and Devel-
According to the definition of BCA (2017b), PPVC is a construc- opment Board (HDB) of Singapore is another local authority have
tion method whereby free-standing volumetric modules (complete interest in PPVC (Lim, 2016a). HDB deems PPVC as a productive and
with finishes for walls, floors, and ceilings) are manufactured and helpful instrument for its HDB apartment development. HDB is
assembled in an accredited fabrication facility in accordance with currently carrying out some research initiatives to develop an
any accredited fabrication method, and then transported to site and integrated, automatic PPVC production system (Lim, 2016a). To sum
installed to form a building. Different from conventional con- up, under the enthusiasm from the local authorities, PPVC is being
struction methods in which design, engineering, and construction actively advocated and promoted in Singapore.
activities are consecutive, PPVC allows works to be done in parallel.
Thus, it can help expedite the implementation of the project 2.3. The adoption of PPVC: constraints and mitigation strategies
significantly and thereby increase productivity (Saad, 2016).
Moreover, PPVC can result in tangible cost savings due to the less Given the limited amount of research, the constraints to the
manpower and equipment required onsite compared to traditional adoption of PPVC and the relevant mitigation strategies can hardly
construction methods (Bernstein et al., 2011). Furthermore, by be extracted from the existing literature directly. However, there is
carrying out the majority of the work in a controlled, factory considerable documentation on generic off-site construction
environment, PPVC is able to provide a healthier and safer working methods in current literature, which is also applicable to PPVC to a
environment for workers, which also addresses the safety concern certain extent. Thus, this study conducted a comprehensive
B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193 185

literature review of generic offsite construction methods trying to identified and assessed the constraints associated with the adop-
help identify the constraints and mitigation strategies specific to tion of modular construction, and the top six constraints were
the adoption of PPVC. revealed as key decisions of construction methods made by
Literature review shows that several studies have done excellent designers without the involvement of contractors, the wrong
work in summarizing the constraints, challenges, barriers, and perception of modular construction from the owner, non-
limitations to the used of generic off-site construction methods. availability of prefabrication unit in the project vicinity, restricted
Arashpour et al. (2016) summarized the constraints on using offsite site layout, decreased flexibility for changes during project imple-
construction approach, which includes longer lead times due to a mentation, and difficulty in carrying out onsite modifications.
lack of coordination between onsite demand and offsite construc- Jaillon and Poon (2010) conducted a questionnaire survey among
tion, higher maintenance costs for end users caused by low utili- the construction professionals who expressed that site storage and
zation of expensive manufacturing resources, and inconsistent access, increased time for design, and the lack of flexibility were the
quality due to high variety of customized products and inefficient major limitations to the adoption of prefabrication. Tam et al.
floor control. Kamali and Hewage (2016) reviewed the challenges (2007) investigated the hindrances in applying prefabrication,
for using modular construction method and found that the main and the top three hindrances were found to be inflexible for design
challenges pointed to project planning, transportation restraints, changes, lack of research information, and higher initial construc-
negative perceptions from the public, site constraints, high initial tion cost. Although it looks that considerable efforts have been
cost, and increased coordination and communication required. Mao made to investigate the constraints, challenges, barriers, and limi-
et al. (2015) carried out a questionnaire survey and examined the tations on using off-site construction methods, it should be noted
major barriers that impede the use of offsite construction method that none of them is specific to PPVC. Nevertheless, this compre-
in the Chinese construction industry. They found that the top three hensive review provides a good reference for this study to identify
major barriers were the absence of governmental incentives and the constraints specific to PPVC. Finally, a list of 18 constraints that
regulations, extremely high upfront cost, and practitioners’ may hinder the adoption of PPVC was extracted from literature
dependence on conventional construction methods. Similarly, review and presented in Table 1.
Rahman (2013) conducted a critical review to investigate the To address these constraints, challenges, barriers, and limita-
barriers to the implementation of modern construction methods tions mentioned above, various mitigation strategies have been
(mostly are offsite construction methods). He found the barriers proposed by the academia. For instance, a large number of studies
mainly lie in eight perspectives including cost-related issues, proposed to use information technologies such as 3D visualization,
motivation and culture, skills and experience, market demands, product information model, and building information modeling
tools and standards, industry related issues, inflexibility, and (BIM) to tackle the information-related obstacles encountered in
project-specific issues. Chiang et al. (2006) investigated the barriers the implementation of offsite construction projects (Han et al.,
that hinder offsite construction method to be adopted in the public 2015; Kim et al., 2016; Ramaji and Memari, 2016; Zhang et al.,
housing construction sector of Hong Kong, which were found to be 2016; Zhao, 2017). Also, as a result of shifting site activities to
difficulties in transporting the heavy and bulky prefabricated factories, offsite construction needs early confirmation of design,
modules, gaining access to buildings for large modules, additional construction details, and construction sequences to avoid any
labor training, and poor jointing of prefabricated. Azhar er al. (2013) abortive works that will be costly and time-consuming. In this

Table 1
Constraints on using PPVC.

Code Constraints References

C1 Decreased flexibility for design changes later Azhar et al. (2013); De La Torre (1994); Jaillon and Poon (2010); Kamali and Hewage
(2016); Lu (2007); Mao et al. (2015); Rahman (2013); Tam et al. (2007)
C2 Unsupportive decision made by designers Azhar et al. (2013)
C3 Limitations to design due to transportation restrictions (e.g. modules' size) Mao et al. (2015); Rahman (2013)
C4 Restricted site layout (e.g. lack of storage space for PPVC modules/lack of Azhar et al. (2013); Jaillon and Poon (2010); Kamali and Hewage (2016); Mao et al.
space to unload and move the modules) (2015); Tam et al. (2007)
C5 Lack of PPVC experiences in term of design Jaillon and Poon (2010); Mao et al. (2015); Rahman (2013); Tam et al. (2007)
C6 Lack of PPVC experiences in term of installation Chiang et al. (2006); Jaillon and Poon (2010); Mao et al. (2015); Rahman (2013); Tam
et al. (2007)
C7 Need for additional protection materials for PPVC modules De La Torre (1994)
C8 Increased transportation and logistics considerations Haas and Fagerlund (2002); Kamali and Hewage (2016); Mao et al. (2015); McGraw
Hill (2011)
C9 Transportation restrictions due to rules and regulations Chiang et al. (2006); Haas and Song (2002); Jaillon and Poon (2010); Kamali and
Hewage (2016); Mao et al. (2015)
C10 Lack of awareness of PPVC's benefits among owners/developers Azhar et al. (2013); Mao et al. (2015)
C11 Increased organizational requirements (e.g. changing roles of project Haas and Fagerlund (2002); Mao et al. (2015)
participants/increased complexity of procurement and contracting issues)
C12 Requirement for early commitment Azhar et al. (2013); Blismas et al. (2005); Jaillon and Poon (2010); McGraw Hill (2011);
Rahman (2013)
C13 The need for additional project planning and design efforts Construction Industry Institute (1992); De La Torre (1994); Haas and Song (2002);
Haas and Fagerlund (2002); Lapp and Golay (1997); Lu (2007)
C14 Extensive coordination required prior to and during construction Arashpour et al. (2016); De La Torre (1994); Haas and Song (2002); Haas and
Fagerlund (2002); Kamali and Hewage (2016); Lu (2007)
C15 Higher initial cost to conventional construction method (Gibb and Isack, 2003); Jaillon and Poon (2010); Kamali and Hewage (2016); Lapp and
Golay (1997); Mao et al. (2015); (Pan et al., 2007, 2008); Rahman (2013)
C16 Higher construction costs to the conventional construction method De La Torre (1994); Jaillon and Poon (2010); Mao et al. (2015); Rahman (2013); Tam
et al. (2007)
C17 Require more communication among all stakeholders Haas and Fagerlund (2002); Kamali and Hewage (2016)
C18 Complex code compliance and inspection process Mao et al. (2015); Rahman (2013)
186 B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193

regard, researchers suggested establishing an effective collabora- adopted strategy to validate and refine the information retrieved
tion among project key participants in early project planning phase from literature review, as it is a good opportunity for a research
(Goh and Loosemore, 2017; Said, 2015, 2016). Furthermore, work to take in the valuable views from the practice (Li et al., 2016a;
regarding the typical problem of transportation encountered by Ozorhon et al., 2010; Tran et al., 2015; Zhao et al., 2017). Thus,
offsite construction projects, Khalili and Chua (2013) and Mao et al. following the literature review, this study carried out pilot
(2016) suggested that the modules can be fabricated and assembled interviews with industry experts with the intention of verifying the
proximal to the construction site so that additional transportation constraints and mitigation strategies identified from literature
efforts may be reduced. As for the site constraint issue for offsite review. In this study, three industry experts with experiences in
construction projects, Just-in-Time delivery was proposed as it can local PPVC projects were invited for pilot interviews. All of them are
minimize the on-site storage space and thereby improve site senior members of the Building Innovation Panel, a government
management (Kim et al., 2013; Low and Chuan, 2001; Oral et al., organization dedicated to improving construction productivity
2003; Wu and Low, 2012). Additionally, Tam et al. (2007) and through various innovative technologies including PPVC (BCA,
Wang et al. (2016) suggested developing systems or computer- 2017a). The interview results showed that the constraints and
aided programs to carry out detailed feasibility study (particularly mitigation strategies identified from the literature review were
in the sense of economic analysis) for offsite construction projects applicable to the existing PPVC projects in Singapore and thus could
is a good strategy to guarantee project success. Arashpour et al. be used for further research actions. Nevertheless, the statements
(2017) and Hanna et al. (2017) recommended developing training of some constraints and mitigation strategies were rephrased based
courses/programs for project team and workers to enhance their on interviewees’ comments to increase their comprehensiveness
knowledge and skills with regards to the offsite construction, to and accuracy.
address the constraint of lack of experience. Based on the literature Questionnaire survey is a widely used method to collect pro-
review mentioned above, a total of nine mitigation strategies that fessional views of a certain topic in CEM research (e.g., Azhar et al.,
might be helpful for addressing the constraints associated with 2013; Cheung et al., 2015; Collins et al., 2017; Li et al., 2016c; Liu
PPVC were identified, compiled and listed in Table 2. et al., 2016; Zhao et al., 2014). Thus, this study used questionnaire
survey to gather professionals' perceptions of constraints and
3. Methods and data presentation mitigation strategies. Based on the results of pilot interviews, a
questionnaire was developed, which consisted of three sections.
3.1. Data collection and presentation The first section was to record respondents’ background informa-
tion including their employer types and years of experience in the
This study adopts an approach that employs various qualitative construction industry and the PPVC field. The second section asked
and quantitative research methods including literature review, respondents to rate the constraints using a five-point rating scale
pilot interviews, questionnaire, and case study. Conducting litera- (i.e., 1 ¼ very insignificant, 2 ¼ insignificant, 3 ¼ slightly significant,
ture review is an effective approach to learn about a topic regarding 4 ¼ significant, and 5 ¼ very significant). The third section reques-
its substantive findings and theoretical and methodological ted respondents to rate the effectiveness of the mitigation strate-
features (Deng et al., 2014; Lu et al., 2014; Xue et al., 2010; Yuan gies using another five-point rating scale (i.e., 1 ¼ very ineffective,
et al., 2015). Therefore, this study conducted a comprehensive 2 ¼ ineffective, 3 ¼ slightly effective, 4 ¼ effective, and 5 ¼ very
literature review first to identify the constraints and mitigation effective).
strategies that are associated with the adoption of PPVC method, as This study identified 100 institutions having experiences in
presented in the last section. To ensure the comprehensiveness of undertaking prefabrication projects in Singapore as potential re-
coverage, a wide range of literature was searched for review, spondents and emailed them the questionnaires for data collection.
including books, journal articles, documents from relevant To ensure a high response number, phone calls and email re-
authorities, information from internet websites, as well as both minders were sent every week if the dispatched questionnaires
unpublished and published theses from universities around the were not returned before the due date. Finally, a total of 41 re-
world. sponses were received, representing a response rate of 41 percent
In construction engineering and management (CEM) research, for this survey. It is noteworthy that this number has already been a
doing interview with experienced industry experts is a widely relatively high response rate as the normal one for a survey in the

Table 2
Mitigation strategies for the constraints on using PPVC.

Code Mitigation strategy References Targeted constraint

MS1 Encouraging close collaborations between project stakeholders during early phase of project Goh and Loosemore (2017); Said (2015, 2016) C1, C2, and C3
MS2 Apply Temporary Occupation License (TOL) to set up temporary worksite in the vicinity of Shi and Sun (2001) C4
the construction site to overcome the restricted site layout issue
MS3 Use of Just-in-Time delivery Kim et al. (2013); Low and Chuan (2001); Oral C4
et al. (2003); Wu and Low (2012)
MS4 Offering training courses for project team and workers to enhance their knowledge and Arashpour et al. (2017); Hanna et al. (2017) C5, C6, and C7
skills
MS5 Fabricate and assemble the module components as close as possible to the construction site Khalili and Chua (2013); Mao et al. (2016) C8 and C9
to reduce transportation effort
MS6 Use of Information Technologies (e.g. electronic file transfer) to overcome the extra Kim et al. (2016); Ramaji and Memari (2016) C10 and C11
requirement of planning, coordination and communication
MS7 Conduct feasibility studies for PPVC method Tam et al. (2007) C12, C13, C14, C15,
C16, C17, and C18
MS8 Develop systems/computer programs to perform detailed economic analyses for both PPVC Wang et al. (2016) C12, C13, C14, C15,
and conventional construction methods C16, C17, and C18
MS9 Use of BIM to improve coordination and facilitate communication among project Kim et al. (2016); Zhang et al. (2016) C12, C13, C14, C15,
stakeholders C16, C17, and C18
B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193 187

Table 3
Profile of the respondents.

Respondent profile Frequency Percentage (%) Cumulative percentage (%)

Respondent's Institution
Governmental agency 1 3 3
Developer 5 12 15
Construction company 21 51 66
Consultancy 6 15 81
Architectural firm 3 7 88
Quantity Surveyor 2 5 93
PPVC Supplier/Manufacturer 3 7 100
Respondent's occupation
Architect 4 10 10
Engineer 13 32 42
Project Manager 7 17 59
Quantity Surveyor 9 22 81
Facility Manager 8 19 100
Years of experiences in the construction industry
1-4 years 16 39 39
5-9 years 7 17 56
>10 years 18 44 100
Years of experiences with PPVC projects
Less than 1 year 27 66 66
2 years 9 22 88
3 years 5 12 100

construction industry is between 20 and 30 percent (Hwang et al., (Minchin et al., 2016). Thus, the first step of data analysis is to check
2014; Jia et al., 2016). The profiles of the respondents and their data's normality. Upon the recommendations of Chou et al. (1998)
institutions are shown in Table 3. It could be noted that the re- and Gel et al. (2007), the commonly used Shapiro-Wilk test was
spondents are from different types of institutions such as govern- conducted to help check data's normality. The null hypothesis of
mental agency, developer, construction company, consultancy, the Shapiro-Wilk test is the population was normally distributed. If
architectural firm, quantity surveyor, and PPVC supplier/manufac- the p-value generated from the test is less than the chosen alpha
turer. Also, the respondents are of different occupational back- level (e.g., 0.05), then the null hypothesis is rejected, and conclusion
grounds such as project manager, architect, quantity surveyor, can be made that the data tested are not normally distributed
engineer, and facility manager. The diversity and heterogeneity of (Villasenor Alva and Estrada, 2009). In this study, a common alpha
the respondent panel can ensure the quality and reliability of the level of 0.05 was used. The test was conducted with the aid of SPSS
collected data and thereby enabling the findings more convincing Statistics 17.0.
(Cao et al., 2016). Although it can be found from Table 3 that the As questionnaire respondents are from different institutions
majority of the respondents have limited years of experience in such as governmental agency, developer, construction company,
PPVC projects, this can be explained by the fact that PPVC was not consultancy, architectural firm, quantity surveyor, and PPVC
introduced to Singapore until very recently (BCA, 2017b). specialist builder, it is necessary to conduct inter-group comparison
In CEM research, case study is a qualitative research method to check whether there are significant differences in respondents’
widely used to cross-check findings obtained from quantitative perceptions in terms of their institutions. Two different statistical
research (Du and El-Gafy, 2015; Hwang et al., 2014; Ozorhon et al., test methods, analysis of variance (ANOVA) and Kruskal-Wallis test,
2014; Zhao and Singhaputtangkul, 2016). Thus, at the last step of were considered to perform the inter-group comparison. ANOVA is
this study, a case study was conducted based on a real-life PPVC a widely used parametric statistical test method that checks the
project named North Residential Hall at Nanyang Technological statistical differences between the means of two or more inde-
University. During the case study, an experienced professional pendent groups (e.g., Caldas et al., 2014; Deng et al., 2012; Xia et al.,
working for this project was contacted and interviewed to capture 2015; Zhao et al., 2014); while Kruskal-Wallis test is a rank-based
the in-depth information of this PPVC project in terms of its con- non-parametric statistical test method that checks the potential
struction procedures, coordination activities, as well as the major differences among two or more different groups (Rajendran et al.,
constraints it was facing. The outputs of the case study are valuable 2009; Tixier et al., 2014). Thus, the data normality test results
as they can further strengthen people’ understanding of PPVC in provided by the Shapiro-Wilk test will determine which method
current practice. will be used for inter-group comparison.
According to Roberts et al. (2016), conducting pairwise com-
3.2. Data analysis methods parison of matched variables is a good strategy to identify the
foremost variables, the core ones that have the highest priority in
Statistical tests were conducted to analyze the data collected terms of ranking and significance in a set of variables. As a result,
from the questionnaire survey. Although the sample size of this pairwise comparisons of matched constraints/mitigation strategies
study (i.e. 41) was not large, statistical analysis could still be per- were carried out to identify the most significant constraints and the
formed because the central limit theorem holds true as long as the most effective mitigation strategies for PPVC. Wilcoxon Signed-
sample size is no less than 30 (Ott and Longnecker, 2015; Zhao et al., Ranks test was considered for the pairwise comparison, following
2016). There are two types of prevailing statistical tests, parametric the recommendations of Darko and Chan (2018) and Shan et al.
statistical tests and non-parametric statistical tests (Kim, 2015). (2017). This is a distribution-free statistical test method that has
Parametric statistical tests have a specific requirement that the data been widely used to compare two matched variables, assessing
to be analyzed must fall in a normal distribution, while non- whether significant difference exists between (Berg, 2016; Lund
parametric statistical tests have no such particular requirement Research, 2013; Wu et al., 2014).
188 B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193

4. Results and discussions considerations”, C12 “requirement for early commitment”, and C15
“higher initial cost to conventional construction method” are top
4.1. Significant constraints on using PPVC five constraints on using PPVC. Furthermore, the Wilcoxon Signed-
Ranks test results in Table 5 show that the assessments to C14 and
Tables 4 and 5 present respondents’ assessments of constraints C13 are statistically higher than the majority of constraints, sug-
as well as the results obtained from the statistical test. Shapiro- gesting they are the most significant constraints on using PPVC. Due
Wilk test results in Table 4 indicate that the data of constraints to the word and space limit, only the top five significant constraints
are non-normal distributed. Therefore, the Kruskal-Wallis test was were discussed in detail in this study.
selected to conduct inter-group comparison, and that the Wilcoxon Receiving the highest assessment of 4.37, C14 “extensive coor-
Signed-Ranks test was selected for variable comparison. The dination required prior to and during construction” was ranked as
Kruskal-Wallis test results in Table 4 reveal that except C7 “need for the most significant constraint on using PPVC. In contrast to the
additional protection materials for PPVC modules”, none of con- conventional construction methods, PPVC involves multidisci-
straints were perceived statistically different by respondents in plinary professionals to work in parallel and collaboratively in
terms of their institution background. Such result implies that the every stage of the project, which means that extensive coordination
assessments of the respondents are basically unanimous and can be among the different project stakeholders is required, to handle the
treated as a whole for analysis. Also, assessment results in Table 4 design, manufacturing, transportation, and installation of the pre-
show that C14 “extensive coordination required prior to and dur- fabricated modules. However, the fragmented and conservative
ing construction”, C13 “need for additional project planning and nature of the construction industry restricts such coordination (De
design efforts”, C8 “increased transportation and logistics La Torre, 1994; Lu, 2007), which impedes the implementation of

Table 4
Assessments and statistical test resutls of constraints.

Code Constraint Mean Rank Shapiro-Wilk test Kruskal-Wallis test


(p-value) (p-value)

C14 Extensive coordination required prior to and during construction 4.37 1 0.000* 0.344
C13 Need for additional project planning and design efforts 4.27 2 0.000* 0.810
C8 Increased transportation and logistics considerations 4.10 3 0.000* 0.153
C12 Requirement for early commitment 4.00 4 0.000* 0.162
C15 Higher initial cost than conventional construction method 3.95 5 0.000* 0.054
C3 Limitations to Design due to transportation restrictions (e.g. modules' size) 3.94 6 0.000* 0.677
C1 Decreased flexibility for design changes later 3.93 7 0.000* 0.403
C9 Transportation restrictions due to rules and regulations 3.80 8 0.000* 0.381
C4 Restricted site layout (e.g. lack of storage space for PPVC modules/lack of space to unload and move the 3.78 9 0.000* 0.499
modules)
C16 Higher construction costs to the conventional construction method 3.71 10 0.000* 0.424
C17 Require more communication among all stakeholders 3.71 10 0.000* 0.242
C18 Complex code compliance and inspection process 3.54 12 0.000* 0.405
C10 Lack of awareness of PPVC's benefits among owners/developers 3.51 13 0.001* 0.263
C5 Lack of PPVC experiences in term of design 3.49 14 0.000* 0.162
C6 Lack of PPVC experiences in term of installation 3.44 15 0.001* 0.829
C2 Unsupportive decision made by designers 3.44 15 0.002* 0.973
C7 Need for additional protection materials for PPVC modules 3.17 18 0.005* 0.026**
C11 Increased organizational requirements (e.g. changing roles of project participants/increased complexity of 3.41 17 0.000* 0.203
procurement and contracting issues)

Note: * The Shapiro-Wilk test was significant at the significance level of 0.05, suggesting the data were not normally distributed.
**The Kruskal-Wallist test was significant at the significance level of 0.05, suggesting statistical difference among respondents from different institutions.

Table 5
The results of Wilcoxon signed-ranks test for constraints.

C14 C13 C8 C12 C15 C3 C1 C9 C4 C16 C17 C18 C10 C5 C6 C2 C7 C11

C14 e 0.285 0.100 0.050 0.028* 0.056 0.014* 0.006* 0.016* 0.002* 0.001* 0.000* 0.001* 0.001* 0.000* 0.000* 0.000* 0.000*
C13 e 0.213 0.114 0.065 0.133 0.031* 0.021* 0.014* 0.006* 0.001* 0.000* 0.001* 0.000* 0.000* 0.000* 0.000* 0.000*
C8 e 0.715 0.399 0.516 0.382 0.058 0.154 0.053 0.039* 0.002* 0.004* 0.005* 0.001* 0.006* 0.000* 0.000*
C12 e 0.701 0.911 0.526 0.315 0.306 0.157 0.073 0.027* 0.009* 0.007* 0.014* 0.032* 0.000* 0.002*
C15 e 0.987 0.809 0.325 0.466 0.040* 0.231 0.009* 0.027* 0.024* 0.014* 0.012* 0.000* 0.001*
C3 e 0.813 0.305 0.287 0.248 0.247 0.018* 0.035* 0.029* 0.013* 0.036* 0.001* 0.010*
C1 e 0.498 0.474 0.211 0.344 0.024* 0.066 0.019* 0.015* 0.029* 0.000* 0.005*
C9 e 0.967 0.699 0.802 0.147 0.145 0.167 0.083 0.615 0.081 0.643
C4 e 0.709 0.725 0.164 0.192 0.172 0.099 0.227 0.023* 0.129
C16 e 0.837 0.319 0.230 0.283 0.213 0.124 0.016* 0.070
C17 e 0.323 0.397 0.243 0.154 0.301 0.003* 0.081
C18 e 0.962 0.815 0.656 0.578 0.049* 0.535
C10 e 0.922 0.631 0.615 0.081 0.643
C5 e 0.790 0.868 0.025* 0.863
C6 e 0.973 0.179 0.867
C2 e 0.240 0.990
C7 e 0.140
C11 e

Note: * The Wilcoxon Signed-Ranks test was significant at the significance level of 0.05, suggesting the two compared variables were statistically different.
B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193 189

PPVC in the current construction business. This result echoes (2013); Blismas et al. (2005); Jaillon and Poon (2010); and
Rahman (2013) and Kamali and Hewage (2016) who highlighted Rahman (2013) who stated that the requirement for an early
that there is an urgent need for more detailed and effective coor- commitment from the project stakeholders is a critical limitation
dination among different project stakeholders in each stage of that inhibits the implementation of offsite construction methods.
modular construction. C15 “Higher initial cost than conventional construction method”
C13 “Need for additional project planning and design efforts” received the fifth rank with an assessment of 3.95, indicating the
was assessed as the second most significant constraint on using high initial cost a major limitation to the use of PPVC. The initial
PPVC, with an assessment of 4.27. The planning and design pro- cost for PPVC projects mainly refers to the expenses for the pur-
cesses of PPVC projects demand early collaboration among chase of prefinished modules as well as for the shipping, which is
different parties such as architects, contractors, and manufacturers, normally higher than those for projects constructed with tradi-
which normally requires additional efforts from different project tional methods. Normally, the modules used by PPVC are very
stakeholders (Azhar et al., 2013; Mao et al., 2015; Rahman, 2013). expensive because they are typically highly completed (mostly
Moreover, due to the unique size and location of each project, the 85e90 of the project work) (Kamali and Hewage, 2017). Further-
building layout for each PPVC project is exclusive. Therefore, the more, the shipping of prefinished modules to site is also costly
relevant planning and design has to be reinvented for each new either from overseas module suppliers or from a local prefabrica-
project. Thus, compared to conventional construction methods, tion yard. Moreover, due to the large size, the prefinished modules
PPVC needs additional project planning and design efforts. This are more prone to shipping damage, thereby making the initial cost
result is in line with Lu (2007) and Jaillon and Poon (2010) who for PPVC projects even higher. This result is in line with numerous
emphasized that the increased workloads of pre-project planning studies who claimed that the high initial cost is a major economic
design are is the biggest obstacle to offsite construction projects. constraint of offsite construction projects (Gibb and Isack, 2003;
C8 “Increased transportation and logistics considerations” were Jaillon and Poon, 2010; Kamali and Hewage, 2016; Mao et al.,
ranked as the third most significant constraint with an assessment 2015; Pan et al., 2007, 2008; Rahman, 2013; Tam et al., 2007).
of 4.10. Transportation logistics have a vital role in undertaking
PPVC projects (Haas and Fagerlund, 2002). Normally, before taking 4.2. Effective mitigation strategies for constraints
any design step, the modular project team needs to examine the
limitations of module transportation in the relevant area, because Tables 6 and 7 presents the respondents' assessments to the
in most cases there is some special traffic control requirement on proposed mitigation strategies as well as the relevant statistical test
transporting heavy and bulky articles in densely populated areas results. As indicated in Table 6, Shapiro-Wilk test results reveal a
(Rahman, 2013). Additionally, the module's dimensional constraint non-normal data distribution, therefore Kruskal-Wallis test and
might be another transportation barrier which can be dictated by Wilcoxon Signed-Ranks test were selected to proceed inter-group
transportation regulations sometimes (Tam et al., 2007). Also, comparison and variable comparison, respectively. According to
module manufacture itself may have a maximum limit of distance the results of Kruskal-Wallis test, except MS1 “encouraging close
for transportation (Jaillon and Poon, 2010). Similar conclusions collaborations between project stakeholders during early phase of
were also obtained by Mao et al. (2015) and Kamali and Hewage project,” the rest mitigation strategies received consistent assess-
(2016) who claimed that transportation restraints were a chal- ments from respondents, indicating that respondents’ perceptions
lenge for using modular construction. of mitigation strategies are basically unanimous. Assessment re-
C12 “Requirement for early commitment” ranks fourth with an sults in Table 6 show that MS1 “encouraging close collaborations
assessment of 4.0, implying that the early commitment is another between project stakeholders during early phase of project,” MS9
significant constraint on using PPVC. According to BCA (2017b), “use of BIM to improve coordination and facilitate communication
PPVC requires early involvement of project design and planning among project stakeholders,” and MS4 “offering training courses
because the precast components and modules need to be manu- for project team and workers to enhance their knowledge and
factured before construction starts. However, the respondents skills” are top three effective mitigation strategies that can over-
attending the survey maintained that the intensive upfront come the constraints of PPVC. Moreover, the Wilcoxon Signed-
commitment in PPVC projects was inflexible, particularly regarding Ranks test results in Table 7 reveal that the assessments to MS1,
the possible changes in the later project stages, which becomes an MS9, and MS4 are statistically higher than the majority of mitiga-
obstacle to using PPVC. Such results are also found by Azhar et al. tion strategies, indicating they are the most effective mitigation

Table 6
Assessments and statistical test resutls of mitigation strategies.

Code Mitigation strategy Mean Rank Shapiro-Wilk test Kruskal-Wallis test


(p-value) (p-value)

MS1 Encouraging close collaborations between project stakeholders during early phase of project 4.17 1 0.000* 0.046**
MS9 Use of BIM to improve coordination and facilitate communication among project stakeholders 4.07 2 0.000* 0.437
MS4 Offering training courses for project team and workers to enhance their knowledge and skills 4.02 3 0.000* 0.544
MS3 Use of Just-in-Time delivery 3.68 4 0.000* 0.684
MS5 Fabricate and assemble the module components as close as possible to the construction site to reduce 3.63 5 0.000* 0.310
transportation effort
MS6 Use of Information Technologies (e.g. electronic file transfer) to overcome the extra requirement of planning, 3.63 6 0.000* 0.839
coordination and communication
MS8 Develop systems/computer programs to perform detailed economic analyses for both PPVC and conventional 3.63 7 0.000* 0.673
construction methods
MS7 Conduct feasibility studies for PPVC method 3.56 8 0.000* 0.316
MS2 Apply Temporary Occupation License (TOL) to set up temporary worksite in the vicinity of the construction 3.46 9 0.001* 0.425
site to overcome the restricted site layout issue

Note: * The Shapiro-Wilk test was significant at the significance level of 0.05, suggesting the data were not normally distributed.
**The Kruskal-Wallist test was significant at the significance level of 0.05, suggesting statistical difference among respondents from different institutions.
190 B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193

Table 7 several vocational education institutions such as Institution of En-


The results of Wilcoxon signed-ranks test for mitigation strategies. gineers Singapore Academy and BCA Academy, and are highly
MS1 MS9 MS4 MS3 MS5 MS6 MS8 MS7 MS2 acknowledged by trainees (BCA Academy, 2015; The Institution of
MS1 e 0.381 0.568 0.005* 0.014* 0.002* 0.003* 0.001* 0.001*
Engineers Singapore (2017)).
MS9 e 0.741 0.046* 0.039* 0.006* 0.007* 0.001* 0.004*
MS4 e 0.112 0.055 0.043* 0.030* 0.008* 0.012*
MS3 e 0.826 0.777 0.717 0.562 0.292 5. Case study: North Hill Residential Hall at Nanyang
MS5 0.974 0.958 0.785 0.380
e
Technological University
MS6 e 0.982 0.439 0.386
MS8 e 0.439 0.325
MS7 e 0.659 This case study is based on a real PPVC project named North Hill
MS2 e Residential Halls conducted in Nanyang Technological University,
Note: * The Wilcoxon Signed-Ranks test was significant at the significance level of Singapore. This project is Singapore's first public high-rise building
0.05, suggesting the two compared variables were statistically different. that constructed based on the prefabrication of modular elements
assembled in an off-site factory. Completed within 19 months, the
strategies against the constraints to PPVC. Due to the word and project consisted of six 13-storey blocks which are able to accom-
space limit, only the top three most effective mitigation strategies modate more than 1850 students overall. It is also a one-stop in-
were discussed in detail in this study. tegrated hub, comprising a multipurpose hall, fully-equipped gym,
MS1 “Encouraging close collaborations between project stake- eateries, sky lounges and rooftop gardens with barbecue pits. To
holders during the early phase of project” was ranked first with the better understand the construction procedures, coordination and
highest assessment of 4.17, indicating that collaborations among constraints faced in this PPVC project, an interview was conducted
project stakeholders were perceived to be the most effective with a PPVC specialist involved in this project.
strategy in mitigating constraints impeding PPVC. This is because, According to the interviewee, the location and the size of tower
in a PPVC project, multidisciplinary professionals to work concur- cranes, as well as the delivery routes and the pick-up and unloading
rently during the early project phases such as planning and design, points for trucks, were confirmed in the early stage of site prepa-
which makes close and effective collaborations from different ration. Mock-up modules were manufactured first before the actual
project stakeholders a necessity rather than an option for PPVC production of modules to obtain the approval from the client in
projects. BCA (2017b) also emphasized that the needs of upfront order to avoid the possible disputes in the future. After that, the
planning and coordination among stakeholders is the inherent approved modules were manufactured and prefabricated at four
traits of PPVC method and that the success of PPVC project needs locations including Singapore, Malaysia, Taiwan and mainland
the support and collaboration between project participants. Simi- China. Subsequently, the finished modules were transported to a
larly, Said (2015) highlighted that the close collaborations among temporary site at Jurong Island, Singapore. During this process,
project stakeholders would lead to positive impacts including time, inspectors were hired to do inspections at the manufacturing fac-
cost, quality and risk on the prefabrication projects. tories and Jurong temporary site to ensure the compliance of the
MS9 “Use of BIM to improve coordination and facilitate completed modules to the requirements stipulated in the binding
communication among project stakeholders” was assessed as the contract. After inspection, the modules were transported to the site
second most effective mitigation strategy with an assessment of for installation. As for module transportation, the Just-in-time de-
4.07. Without any doubt, the needs for early involvement and livery was selected, by which about six modules were delivered
commitment in the early stage of PPVC projects leads to more from the Jurong temporary site to NTU site in one day. The number
communication among project players. As such, it gives rise to the of modules per trip varied according to the size. The delivery of
adoption of BIM, which serves as an information platform to bridge modules was scheduled only on days with suitable weathers.
the communication gaps between project stakeholders and Overall, 1213 modules were used in this project. To ensure smooth
enhance the interdisciplinary coordination. Also, according to Lu coordination and accurate sequencing of installation, unique codes
and Korman (2010), the mechanical, electrical and plumbing co- were used and printed on every single module. Also, connection
ordination process can be improved significantly with the adoption details were all initially incorporated into the steel frame, thereby
of BIM as it changes the way engineers and contractors interact allowing easier access for workers to make the on-site connections.
with each other. This is also supported by Goh and Loosemore Figs. 1e3 depict the core processes of this PPVC project, including
(2017) who suggested that leveraging on BIM can improve coor-
dination and allow project stakeholders better understand the
geometry of modules before fabrication. Singh et al. (2015) also
highlighted that, by integrating modular construction rules with
BIM, designers can automate complex modeling and documenta-
tion activities, thus enhancing the design process.
Receiving an assessment of 4.02, MS4 “offering training courses
for project team and workers to enhance their knowledge and
skills” was ranked as the third most effective strategy in mitigating
the constraints to the use of PPVC. In this study, lack of PPVC ex-
periences in terms of design and installation was found to be major
limitations to the adoption of PPVC. This is a very critical issue as it
may lead industry practitioners back to the conventional con-
struction method again. Thus it is imperative to launch a series of
training courses for professionals to help improve their knowledge
and skills related to the implementation of PPVC. This can allow
them to better appreciate the technology and to be more confident
in adopting PPVC projects in the future. Currently, in Singapore,
such training courses and workshops have been launched by Fig. 1. Module manufacture at factory.
B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193 191

somewhat affects the schedule performance of the project. Another


significant constraint is transportation. Normally, the delivery of
the modules to the site needs to be done by the oversized heavy
vehicles which may slow down the urban traffic and affect road
structured due to their large dimension and heavyweight. There-
fore, the movement of such vehicles is strictly regulated by the local
transportation authority. In Singapore, each movement of the
oversized heavy vehicle must apply for approval three working
days before the intended date of travel and must follow the
approved route (Land Transport Authority, 2016). This also brought
some inconvenience to the implementation of this project. Refer-
ring to the constraints mentioned by the interviewee, it could be
noted that they are mainly associated with problems of cost,
additional efforts on planning and design, extensive coordination
and communication among project stakeholders, and trans-
portation and logistics, which are generally in line with the findings
obtained from the questionnaire survey. This proves that the
Fig. 2. Transporting modules to temporary site at Jurong, Singapore. findings from the questionnaire survey are reliable.

6. Conclusions and recommendations


module manufacture, module transportation, and module
installation. Under the circumstances that PPVC gains more interests from
In addition to construction procedures, the interviewee also the industry, this study aimed to explore the significant constraints
highlighted several constraints facing the project. For instance, as that limit the adoption of PPVC in construciton projects and to
Singapore is a city-state with limited industrial capacity, the vast propose a group of mitigation strategies that can help address these
majority of the modules required by this project had to be manu- constraints. By conducting a comprehensive literature review and
factured overseas and then imported to Singapore, which increased administering an empirical questionnaire survey to the experi-
the project's initial cost dramatically. Also, as this PPVC project enced industry professionals, this study identified 18 significant
needs the planning and design to be finalized and confirmed prior constraints that impede the adoption of PPVC, and also came up
to construction and only allow limited opportunities for changes with nine mitigation strategies responding to the constraints. The
during project construction, the project team had to expend survey results revealed that the top five significant constraints were
considerable time and efforts on project design and planning to “extensive coordination required prior to and during construction,”
make sure they are correct and feasible. This process resulted in a “need for additional project planning and design efforts,”
lot of additional workloads, particularly in terms of the coordina- “increased transportation and logistics considerations,” “require-
tion and communication among different project stakeholders (e.g., ment for an early commitment,” and “higher initial cost than con-
developers, architects, engineers, and contractors), which ventional construction method.” The top three most effective

Fig. 3. Module installation at site.


192 B.-G. Hwang et al. / Journal of Cleaner Production 183 (2018) 183e193

mitigation strategies were found to be “encouraging close collab- definition and assessment tool for small industrial construction projects.
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