Improving Flow in Concrete Constructions by Avoiding Spatial Conflicts Between Pour Cycles

Supervisors and formwork engineers divide construction sections into multiple pour cycles in order to achieve a good production flow in concrete constructions. A pour cycle consists of one or more disconnected casting segments. Casting segments in the successor pour cycle often fill the gaps between the disconnected casting segments in the predecessor pour cycle. We call such a meeting of two neighbour casting segments “topological dependency” because it effects spatial conflicts between pour cycles and different trades cannot work on the next casting segment until the previous ones are completely finished. Because of the long curing times, trade crews have to wait or move to other locations. In this research, we introduce a new structure of a cycle planning option, which can avoid such spatial conflicts. We evaluated our cycle planning option by using a stochastic discrete event simulation model and compared it with three practical cycle planning options from one supervisor and two formwork engineers. The criteria for the evaluation were the total construction time as well as the stable production rate and balanced work. In addition, we discuss the potential benefit by using a mix of concrete precast elements and casting segments to achieve an even better production flow.