When buildings are made the old-fashioned way, small mistakes in size or shape (like a wall leaning slightly or a column not being perfectly straight) are expected. Engineers know how to calculate these errors when checking if the building is safe.
But in Modular Integrated Construction (MiC), buildings are made from factory-built modules. These modules are very precise, but they still aren’t perfect. Even tiny factory errors, plus bumps during transportation and installation, can make modules slightly bent, tilted, or misaligned. These little mistakes are called initial geometric imperfections.
The problem is, old building design methods don’t work well for MiC because they focus on single pieces (like just one column), not on the whole module. If engineers ignore how these small errors add up across a module, they could design a structure that doesn’t behave as expected.
So, this study created mathematical models to connect small factory errors with the overall module shape problems. They tested these models using computer simulations (Monte Carlo simulations) to predict how much a module might be “off” in real life. With this, engineers can:
- Know how precise factories need to be when making modules.
- Reduce wasted time and rework from mistakes.
- Design safer, more efficient modular buildings.
In short: Even though modular buildings are super precise, they still have small flaws. This research helps engineers calculate and plan for those flaws so the buildings stay strong and safe.
Initial geometric imperfections of modules in modular integrated construction structures
https://doi.org/10.1016/j.engstruct.2025.121406
2025