ArticlePDF Available

Optimized Reinforcement Detailing Design for Sustainable Construction: Slab Case Study

Authors:

Abstract and Figures

Reinforced steel rebar is commonly supplied in one-dimensional stocks and typically designed for and installed in various structural components in civil and industrial construction. Surplus reinforcement constitutes a major fraction of construction generated waste. Cutting one-dimensional stocks to suit construction project requirements results in cutting losses. Therefore, reducing steel waste (or minimizing cutting losses) has long been the focus of academic research in one-dimensional stock design and cutting problems. Previous research developed mathematical models in an attempt to analytically minimize cutting losses based on preliminary engineering designs, but little insight has been provided on how to integrate minimization of cutting losses and engineering design into an integrated optimization problem, let alone considering minimizing total steel rebar installation cost as a parallel objective. The sustainability issue in regard to balancing reinforcement waste and crew installation costs on the basis of optimized engineering design has yet to be addressed. This study introduces a Mixed Integer Programming (MIP) approach to generate optimal cutting patterns, minimum cutting losses and associated total installation cost. A reinforced concrete slab case is adopted as a test to show that the proposed methodology is capable of producing optimal tradeoff solutions in slab reinforcement detailing design, resulting in less wastage and lower crew installation cost.
Content may be subject to copyright.
Procedia Engineering 145 ( 2016 ) 1478 1485
1877-7058 © 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of ICSDEC 2016
doi: 10.1016/j.proeng.2016.04.186
ScienceDirect
Available online at www.sciencedirect.com
International Conference on Sustainable Design, Engineering and Construction
Optimized Reinforcement Detailing Design for Sustainable
Construction: Slab Case Study
Chaoyu Zhenga, Ming Lub
*
aDepartment of Civil and Envrionmental Engineering, University of Alberta, Edmonton,Canada
bDepartment of Civil and Envrionmental Engineering, University of Alberta, Edmonton,Canada
Abstract
Reinforced steel rebar is commonly supplied in one-dimensional stocks and typically designed for and installed in various structural
components in civil and industrial construction. Surplus reinforcement constitutes a major fraction of construction generated waste.
Cutting one-dimensional stocks to suit construction project requirements results in cutting losses. Therefore, reducing steel waste
(or minimizing cutting losses) has long been the focus of academic research in one-dimensional stock design and cutting problems.
Previous research developed mathematical models in an attempt to analytically minimize cutting losses based on preliminary
engineering designs, but little insight has been provided on how to integrate minimization of cutting losses and engineering design
into an integrated optimization problem, let alone considering minimizing total steel rebar installation cost as a parallel objective.
The sustainability issue in regard to balancing reinforcement waste and crew installation costs on the basis of optimized engineering
design has yet to be addressed. This study introduces a Mixed Integer Programming (MIP) approach to generate optimal cutting
patterns, minimum cutting losses and associated total installation cost. A reinforced concrete slab case is adopted as a test to show
that the proposed methodology is capable of producing optimal tradeoff solutions in slab reinforcement detailing design, resulting
in less wastage and lower crew installation cost.
© 2015 Zheng and Lu. Published by Elsevier Ltd.
Peer-review under responsibility of organizing committee of the International Conference on Sustainable Design, Engineering
and Construction 2015.
Keywords: Steel Rebar; Cutting Loss; Mixed Integer Programming; Multi Objective Optimization
* Corresponding author. Tel.: +1-780-492-5110; fax: +1-780-492-0249.
E-mail address: mlu6@ualberta.ca
© 2016 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/).
Peer-review under responsibility of the organizing committee of ICSDEC 2016
1479
Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
1. Introduction
Materials management is a vital function for improving productivity, safety, quality and sustainability in
construction projects. The management of materials is one crucial part of the construction planning process (i.e.
material planning) as poor materials management can often affect overall construction time, quality and budget. In
construction, material management has become a special activity concerning whether materials are procured,
processed and installed economically and sustainably. It is important to ensure that material waste, crew installation
cost and engineering design are optimally balanced in both reinforcement design and construction.
With the penetration of the Integrated Project Delivery (IPD) concept and the application of BIM technologies,
construction performance is improved by developing a project team that focuses on work processes and decisions
benefitting the entire project rather than individual team members [1]. The integration allows evaluation of numerous
alternatives for design and construction, benefiting reinforcement detailing design, which is indispensably aligned
with pivotal construction issues (i.e. constructability and sustainability). Through interaction of functional activities
between reinforcement management and engineering design by involving experienced engineering designers and
sophisticated field superintendent and foremen, it is anticipated that both material procurement cost and material waste,
along with crew installation cost, can be further reduced while being adherent to design code.
Reinforcing steel installation, as the main component of foundation and superstructure construction, is significant
to construction material management and cost control. Usually, the budget for reinforcing steel accounts for a very
large proportion and can reach as high as 26% in terms of the total project cost [2]. And for some steel structure
dominated buildings, the cost of reinforcing steel can take up to 60% of the entire project cost [3]. On one hand, rebar
waste has a direct effect on the project cost. The generation of waste is inevitable when rebar is supplied in market
available lengths for on-site fabrication [4]. On the other hand, the reinforcing steel layout arrangement ready for crew
installation at the workface (i.e. rebar schedule detailing design) impacts the total material consumption. Standard
lengths for rebar available in the Canadian market are 6 m (20 ft), 9 m (30 ft), 12 m (40 ft), and 18 m (60 ft) [3],
whereas in remote areas where steel manufacturing is undeveloped and transportation is inconvenient, the supply of
reinforcing steel is constrained by limited stock size alternatives (only one or two stock sizes available to order).
Therefore, (1) how to purchase the minimum quantity of reinforcing steel stocks in order to save in the budget, (2)
how to reduce the generated material wastes, and (3) how to detail the reinforcing steel installation for workface
execution, in the context of material management constraints, become significant problems for applied research in
construction engineering.
2. Literature Review
The rebar cutting problem is a typical one-dimensional material cutting optimization problem [4]. The one-
dimensional cutting stock problem (CSP) is known for achieving the best cutting pattern (i.e. how to cut stock rebar)
so as to meet particular construction project requirements, with rebar cutting losses being the major cause of the
construction material waste [5]. The main objective for the classical CSP is minimizing the material waste, when the
order quantity (i.e. required rebar type and length as per design drawings) has been predetermined [2], [4], [69],
resulting in the optimized cutting pattern and corresponding waste. Though significant contributions have been made,
few previous research endeavors have integrated engineering design at the workface level into the cutting optimization
problem.
To minimize either the material waste or the total procurement cost subject to certain market stock sizes is not an
easy task since it is a combinatorial optimization problem under complicated practical constraints. Applying
optimization algorithms on computers is one of the most effective ways to solve those problems. Gilmore and Gomory
[7] introduced an ingenious column generation technique to generate the cutting patterns and solve the cutting
optimization problem. However, the solution using LP to obtain relaxed non-integer solutions would normally depart
from optimality, giving rise to unnecessary waste. Navon et al [10] introduced the benefits of computer-aided design
and computer-aided manufacturing (CAD/CAM) systems for concrete reinforcement; they developed a model for
rebar constructability diagnosis and correction in an object-oriented programming environment. With the swift
development of integer programming techniques, this useful technique has been widely applied in various areas, until
1480 Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
recently; Salem et al [4] adopted an integer programming approach to minimize cutting wastes of reinforcing steel
rebars.
In a nutshell, different from the traditional rebar cutting optimization problem, the problem defined in this research
is a material optimization problem related to temporary engineering design of detailed rebar schedules focusing on
two objectives: (1) to purchase less reinforcing steel (purchasing less reinforcing steel means lower material cost), and
(2) to reduce waste. Thus, there is an urgent need to propose a scientific approach to deal with this new problem in
order to answer the questions: What is the most cost-efficient reinforcing steel detailed arrangement? What is the most
cost-efficient reinforcing steel procurement method? And what is the most environmentally-friendly cutting pattern
to apply to the procured reinforcing steel stocks?
3. Methodology
For different construction components (e.g. pillar, beam, slab, wall, etc.), reinforcement layout design may vary
considerably. Construction components in which rebars are positioned in a two-way arrangement in both vertical and
horizontal directions (e.g. slab and wall) entail high reinforcing steel consumption. In this research, we considered
slab as the typical case in order to illustrate how the rebar stock is cut and how the cut rebar is arranged on slab in
order to meet sustainability requirements (i.e. reducing steel waste and lowering crew installation cost) through
optimization analyses. This research aims to optimize both the rebar detailed arrangement (i.e. lap length, rebar cutting
length, cutting rebar quantities on both directions) on the slab and the cutting pattern for the reinforcing steel stock,
attempting to achieve the objectives of least steel waste and lowest procurement cost. The flowchart of methodology
is shown in figure 1.
Start
Input:
1. Component Configuration
2. Stock Size
3. Lap Length Range
4. Rebar Spacing
5. Unit cost of material of labor
and equipment
6. Other practical constraints
Calculate all the
Layout Arrangement
Possibilities
Output Cutting
Patterns, Total Cost
and Total Waste
Mixed Integer
Programming
Tradeoff Analysis
Have all the Layout
Arrangements been
selected?
Pick one Layout
Arrangement
Alternative
No
Yes
Finish
Drawing Engineering
Sketches for
Records
Fig.1. Flowchart of Methodology
1481
Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
To formulate the optimization problem, the following assumptions were made:
(1) There is only one type of rebar stock size available on the market;
(2) The slab size is longer than the length of rebar stock available on the market, so when we place rebar into the
slab, rebar needs to be spliced up with laps;
(3) Concrete cover depth is neglected in this study because its impact on optimization results is minimal;
(4) Steel rebar is cut in particular lengths at the laydown area on site by experienced ironmen. To meet workface
management requirements, the procured rebar stock needs to be cut into identical lengths along the long direction
or short direction, respectively. However, the cut length for both directions of the slab do not need to be equal.
Given permanent and temporary rebar design specifications, the procured rebar stock size, and other practical
constraints, all the possible combinations of rebar detailing schedules on the slab can be sorted out. By applying mixed
integer programming techniques, minimum cutting losses, optimal cutting patterns and minimum total material cost
can be identified for each alternative. The optimized outputs of each rebar schedule alternative are compared and
tradeoff analyses are conducted between steel waste and total procurement cost in order to identify the best solution.
4. Optimization process
The methodology used to minimize cutting wastes in the industry is adapted from the steel waste reduction method
of one-dimensional stocks in the construction industry [11]. The solution to the problem is divided into the following
two steps.
4.1. Generating rebar detailing schedules
The first step to solve this problem is to generate all feasible rebar detailing schedules. The procedure as adapted
from Pierce [12] can be used to generate all the efficient feasible solutions. Figure 2 and Figure 3 are instrumental in
understanding the basics of slab rebar placement temporary design.
The rebar detailing schedule is determined by two integer parameters ݊ and ݊. Note that Ȁ൑
௫ି௠௔௫ and ܾȀܮ൑
൑
௬ି௠௔௫, and ݊, ݊௫ି௠௔௫, ݊, ݊௬ି௠௔௫belong to positive integers setכ. So the
number of feasible combinations of rebar detailing schedules ܰ௟௔௬௢௨௧can be denoted by the following equation:
ܰ௟௔௬௢௨௧ ൌ(݊௫ି௠௔௫ െȀ൅ͳ݊௬ି௠௔௫ െȀ൅ͳ
(1)
where ݊ is the cutting rebar quantity in one row of long direction while ݊ is the cutting rebar
quantity in one row of short direction; ݊has a lower bound equal to round up (a/L) and a upper
bound equal to ௫ି௠௔௫ (determined by the superintendent for practical concerns); ݊has a lower
bound equal to round up (b/L) and a upper bound equal to݊௬ି௠௔ (same as௫ି௠௔௫); L is stock
length; a is the width of the slab; b is the length of the slab; and c is the rebar spacing along both
long and short direction.
b
a
c
c
Fig.2 Rebar Layout Sample
1482 Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
Fig.3 Rebar Lap
4.2. Mixed Integer Programming
The second step after generating the rebar detailing schedule is to formulate the mixed integer programming (MIP)
model, as follows:
1. Decision variables: to assign decision variables for each pattern (i.e. a particular rebar detailing schedule). At
the end of the solution, the final values of decision variables would inform the detailed rebar configurations ready for
cutting leading to the minimum possible waste. The decision variables are (1) cutting length of the rebar arranged in
the long direction of the slab, denoted asݔ; (2) cutting length of the rebar arranged in the short direction of the slab,
denoted asݕ; (3) the quantity of ݔ long cutting rebar associated with cutting pattern i, denoted as ݎ; and (4) the
quantity of ݕ long cutting rebar associated with cutting pattern i, denoted as ݏ. i is the sequence number of a cutting
pattern in connection with a particular rebar detailing schedule.
Variables ݔ and ݕ are fractional numbers while ݎ and ݏ are integer numbers. Thus, the defined problem is a mixed
integer programming (MIP) problem. These four variables are solved for each cutting pattern of a certain rebar
detailing schedule by iteration. The values of the MIP solution are further used to calculate total waste and total cost.
2. Objective function: the objective is to minimize total cutting losses, which can be written as:
Minimize σݓݖሺσݖݎെ݉
כ݊כݔ൅൫σݖݏെ݉כ݊൯כݕ
(2)
where ݓ is the total cutting losses of cutting pattern i; ݖ is the quantity of cutting pattern i; ݉ is
the rows of rebar in short direction of the slab and ݉ݎ݋ݑ݊݀ݑ݌ሺܾȀܿሻ ͳ; m2 is the rows of
rebar in long direction of the slab and ݉ݎ݋ݑ݊݀ݑ݌ሺܽȀܿሻ ൅ ͳ.
The objective function considered both cutting losses σݓݖǡand surplus cutting lengths in both directions denoted
asሺσݖݎെ݉
כ݊כݔ൅൫σݖݏെ݉כ݊൯כݕ. Note surplus cutting lengths are redundant for cutting rebar,
which is cut from rebar stock by default once cutting patterns are defined (typically for spare use).
3. Constraints: after setting up the objective function, some constraints must be fulfilled. The constraints are simply
to satisfy the demand of the constant cutting length (i.e. ݔ and ݕ) along both directions, which can be given as Eq.(3):
෍ݖݎ൒݉
כ݊
෍ݖݏ൒݉
כ݊
(3)
Additional constraints should be set up to ensure that the lap length is within the range given by design code. The
lap length along the long direction can be formulated as ݔൈ݊
െܽȀ݊െͳ, while the lap length along the short
direction can be formulated as ൫ݕ ൈ ܾ݊൯Ȁ൫݊െͳ. Then the lap constraint can be given as Eq.(4):
݈ݔൈ݊
െܽȀ݊െͳ൏݈
݈൏൫ݕൈ݊
ܾ൯Ȁ൫݊െͳ൏݈
(4)
where ݈ is the lower bound of lap length range; ݈ is the higher bound of lap length range.
1483
Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
4.3. Multi objective optimization
The main objective of this multi-objective optimization problem is to minimize the cutting losses (i.e. waste) of
rebar stocks and minimize total rebar installation cost (i.e. material, labor and equipment). For the multi objective
optimization problem, a Pareto optimal solution is commonly applied to simultaneously optimize each objective [13].
Once cutting pattern configuration variables are solved by applying MIP, total losses and total installation cost of
all the possible rebar detailing schedules can be calculated in Eq.(5) and Eq.(6), as follows:
(5)
(6)
Note σݖ is the total number of rebar stock; ൣ݉݊Ȃͳ൅݉ൈ൫݊െͳis the quantity of laps and stock
cuts;ൣ݉ൈ݊൅݉ൈ݊ is the quantity of cutting rebar.
After cutting losses and total installation cost of all the possible rebar detailing schedules are calculated, the
solutions are sorted by assigning a rank that represents the non-domination of each solution compared to the other
solutions. Note the non-domination is the number of times that the objective values of a certain solution is smaller
than all other possible solutions. The best solutions are then selected by comparing the ranks of all the possible
solutions. The optimization process is illustrated with a flowchart shown in Figure 4:
Population of Generated Solutions
Solution 1: Waste w1; Cost: c1
Solution 2: Waste w2; Cost: c2
Solution 3: Waste w3; Cost: c3
Solution 4: Waste w4; Cost: c4
Solution 5: Waste w5; Cost: c5
ĂĂ
Start
Assign ranks to solutions
Solution 1: Rank: 3;
Solution 2: Rank: 1;
Solution 3: Rank: 15
Solution 4: Rank: 9
Solution 5: Rank: 20
ĂĂ
Pareto optimal
solution Finish
Calculate non-domination
Solution 1: Waste 4; Cost Rank: 7
Solution 2: Waste 8; Cost Rank: 20
Solution 3: Waste 14; Cost Rank: 3
Solution 4: Waste 7; Cost Rank: 3
Solution 5: Waste 1; Cost Rank: 7
ĂĂ
Fig.4 Flowchart of Multi Objective Optimization Process
5. Case study
To illustrate and verify the proposed approach, a case study based on a reinforced concrete (RC) slab was chosen.
The RC slab is the work package of a one-story garage building construction in Alberta, Canada. The RC slab which
is 70 feet long and 55 feet wide is reinforced with steel rebar along both long and short directions. The steel rebar is
placed on the slab spaced at 1 foot along both directions. Confirmed by an experienced field engineer, a maximum of
6 steel rebars of identical length is allowed to be placed along the long direction while a maximum of 5 steel rebar of
identical length is allowed to be placed along the short direction. Lap length is from 35d to 45d (d is the diameter of
rebar). Due to resource constraints, the only available steel stock size is 20M rebar which is 30 feet long. The material
manager and the superintendent would both benefit from identifying the optimized solution for the rebar detailing
schedule on the slab in terms of minimized cutting losses and total installation cost.
In the case study, the parameters of the objective function are determined by empirical and historical data. Steel
cost for 20M rebar is $1/ft; diameter of 20M rebar is 0.064 feet; ironman hourly rate is $60/hr; cutting machine hourly
rate is $155/hr; average cutting time for one cut is 3 mins including loading, cutting and unloading; ground labor
hourly rate is $45/hr; moving and placing one cutting steel rebar (regardless of length) consumes an average of 5 mins;
tying one steel rebar lap consumes an average of 3 mins; working efficiency factor is 0.8; and 2 ironmen and 3 ground
laborers make up the crew.
1484 Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
By inputting the parameters along with mathematical formulations and equations into the Excel Solver interface,
the optimized rebar detailing schedule can be obtained. By listing all the feasible layout arrangement patterns and
undergoing the MIP process one by one, rebar detailing schedules and corresponding total cutting losses and total cost
were obtained given certain settings of input data. A total of 16 alternatives of the slab rebar detailing schedule are
obtained from optimization analysis. Among the 16 options, Pattern No.14 has the minimum percentage of cutting
losses (i.e. actual lengths of cutting losses over total stock lengths), being the most environmentally-friendly and
sustainable solution; Pattern No.1 has the minimum total cost valued at $17,246, which is the most cost-effective
option. The parameters are calculated and tabulated in Table 1.
Table 1. Steel Layout Arrangement Pattern Comparison
Pattern No.
nx
ny
Cutting
Losses (%)
Non-Domi.
(1)
Total Cost ($)
Non-Domi
(2)
Non-Domi
(1)+(2)
Rank
1
3
2
21.72%
8
17,246
15
23
3
2
3
3
29.71%
4
20,651
14
18
6
3
3
4
14.49%
12
20,696
13
25
1
4
3
5
18.86%
9
23,261
10
19
5
5
4
2
34.07%
2
21,563
12
14
8
6
4
3
27.56%
7
24,968
8
15
7
7
4
4
28.14%
6
25,013
7
13
9
8
4
5
30.88%
3
27,578
3
6
10
9
5
2
42.67%
0
25,880
6
6
10
10
5
3
46.25%
1
29,285
2
3
11
11
5
4
17.96%
10
25,974
5
15
7
12
5
5
28.92%
5
36,095
0
5
10
13
6
2
15.57%
11
23,807
11
22
4
14
6
3
3.11%
15
24,692
9
24
2
15
6
4
8.34%
14
27,258
4
18
6
16
6
5
13.21%
13
29,823
1
14
8
In addition to the two extreme optimal solutions mentioned above, by applying Pareto optimal solution to integrate
the two objectives, tradeoff between the two optimization objectives being analyzed can be made. Planners can analyze
these solutions comprehensively and select a rebar detailing schedule that strikes the optimal balance between
reducing cutting losses and the total installation cost such as Pattern No.3. This solution provides savings of 25% of
total cost compared to Pattern No.14 with an increase of only 10% of the wastage. Similarly, Pattern No.3 provides a
reduction of 7% more wastage than Pattern No.1, which increases the total cost by 12.35%.
The results shown in Table 1 offer a good "sustainable" case: the design optimum selection cannot be based on crew
installation cost alone, or material waste alone; they need to be well balanced. The analysis of this case study
emphasizes the unique and practical traits of the presented approach. It also illustrates how the approach can be
effectively used to identify a wide range of optimal plans of slab steel rebar detailing schedules. Decision makers can
make the best tradeoff decision by selecting an optimal slab rebar detailing schedule that satisfies specific requirements
of the construction project being planned.
6. Conclusion
This research has introduced an optimization method for slab rebar detailing schedule design, giving rise to the
sustainable construction plan featuring the optimal tradeoff between reducing cutting losses and lowering the total
installation cost. In the particular case of a slab rebar design, the concepts of sustainability, integrated project delivery,
and workface engineering design have been materialized in the form of mathematical programming formulations,
resulting in analytical optimal solutions ready for workface execution. In detail, the problem has been formulated in
the form of Mixed Integer Programming and Multi Objective Optimization; the optimal tradeoff plan for selecting
1485
Chaoyu Zheng and Ming Lu / Procedia Engineering 145 ( 2016 ) 1478 – 1485
slab rebar detailing design is thus achievable. Excel Solver is utilized to conduct the optimization in the case study.
To some extent, the proposed methodology has converted an empirical rebar arrangement problem in construction
engineering into an analytical problem for optimization. Further, the approach used for slab in this study can be
replaced by other construction components. To assist in addressing a largely empirical designing problem in a
quantitative fashion, further improvements of the research reported in this paper are anticipated in the future, as
follows:
(1) As the optimization approach cannot be detached from the empirical cost data; it is foreseen that there is a need
to improve the reliability of empirical cost data in order to achieve better optimized solutions in designing the optimal
rebar detailing schedule.
(2) In practice, weighting in regard to relative importance of each objective can be added in order to conduct
weighted tradeoff analysis.
(3) The methodology can be generalized to deal with the rebar detailing schedule design on multiple structural
components in order to maximize the potential of optimization analysis.
(4) A real-world case study, combined with optimization result comparisons with other (conventional) approaches,
could be conducted, attempting to validate the method applicability and effectiveness.
References
[1] C. B. Tatum, “Integrated construction engineering activities to satisfy challenging project objectives,” Constr. Res. Congr. 2012 Constr.
Challenges a Flat World, Proc. 2012 Constr. Res. Congr., pp. 139148, 2012.
[2] S. Kim, W. Hong, and J. Joo, “Algorithms for Reducing the Waste Rate of Reinforcement Bars,” no. May, pp. 1723, 2004.
[3] A. Porwal and K. N. Hewage, “Building Information ModelingBased Analysis to Minimize Waste Rate of Structural Reinforcement,”
J. Constr. Eng. Manag., vol. 138, no. 8, pp. 943954, 2012.
[4] O. Salem, A. Shahin, and Y. Khalifa, “Minimizing cutting wastes of reinforcement steel bars using genetic algorithms and integer
programming models,” J. Constr. Eng. Manag., vol. 133, no. 12, pp. 982992, 2007.
[5] O. Salem, M. Asce, A. Shahin, and Y. Khalifa, “Minimizing Cutting Wastes of Reinforcement Steel Bars Using Genetic Algorithms
and Integer Programming Models,” vol. 133, no. 12, pp. 982993, 2008.
[6] A. a Shahin and O. M. Salem, “Using genetic algorithms in solving the one-dimensional cutting stock problem in the construction
industry,” Can. J. Civ. Eng., vol. 31, pp. 321332, 2004.
[7] P. C. G. E. Gomory, “A Linear Programming Approach to the Cutting Stock Problem,” Oper. Res., vol. 9, no. 6, pp. 849859, 1961.
[8] A. Arbel, “Large-scale optimization methods applied to the cutting stock problem of irregular shapes,” Int. J. Prod. Res., vol. 31, no. 2,
pp. 483500, 1993.
[9] P. Mishra, D. K. Parbat, and J. P. Modak, “Field Data-Based Mathematical Simulation of Manual Rebar Cutting * Satya,” vol. 19, no.
1, pp. 111126, 2014.
[10] R. Navon, Y. Rubinovitz, and M. Coffler, “RCCS: Rebar CAD/CAM System,” Comput. Civ. Infrastruct. Eng., vol. 10, no. 6, pp. 385
400, Nov. 1995.
[11] C. Goulimis, “Optimal solutions for the cutting stock problem,” Eur. J. Oper. Res., vol. 44, no. 2, pp. 197 208, Jan. 1990.
[12] J. F. Pierce, Some large-scale production scheduling problems in the paper industry. Prentice-Hall, 1964.
[13] W. Orabi, K. El-Rayes, A. B. Senouci, and H. Al-Derham, “Optimizing Postdisaster Reconstruction Planning for Damaged
Transportation Networks,” J. Constr. Eng. Manag., vol. 135, no. 10, pp. 10391048, Oct. 2009.
... Previous studies predominantly utilized stock-length rebar to create cutting patterns to minimize cutting waste [11][12][13][14][15][16]. Subsequently, with the introduction of special-length (SpL) rebar, some researchers have successfully integrated stock-length and special-length rebars, leading to an even greater reduction in cutting waste [17,18]. However, certain conditions, such as a minimum order quantity, pre-order time, minimum length, and maximum length associated with acquiring SpL rebar, might differ between steel mills [18]. ...
... However, certain conditions, such as a minimum order quantity, pre-order time, minimum length, and maximum length associated with acquiring SpL rebar, might differ between steel mills [18]. Regarding the lap splice position, most studies examined the lap splice position to optimize rebar-cutting patterns [13][14][15][16][17]. Building codes stipulate lapping zone regulations that govern the position of lap splices during rebar design and arrangement. ...
... The previous optimization studies [11][12][13][14][15][16][17] limited their study, as they primarily focused on minimizing cutting waste, ignoring the potential for reducing rebar usage through the reduction of the number of splices. In support of this viewpoint, Chen and Yang asserted that the RC design should consider as few splices as possible [19]. ...
Article
Full-text available
Rebar usage and cutting waste contribute significantly to global greenhouse gas emissions, mainly CO2 and CH4. Researchers have explored various means to minimize cutting waste; however, these studies have yet to address reducing splices and utilizing a single specific special-length rebar. Hence, this study proposed an algorithm to minimize rebar usage and reduce rebar-cutting waste to less than 1% (near-zero rebar-cutting waste). The algorithm involves two main steps: (1) reducing the number of splices by utilizing special-length rebar and (2) adjusting the rebar accordingly based on the obtained special-length rebar. The algorithm was applied to the column rebars of an RC building to validate its effectiveness. The results confirmed a reduction in rebar usage by 3.226 tons (17.76%), a cutting waste rate of 0.83% (near-zero rebar-cutting waste achieved), a reduction of 11.18 tons in CO2 emissions, and a cost reduction of USD 3741. Employing the proposed algorithm in RC building and structure projects will amplify the corresponding benefits and contribute to the achievement of SDGs adopted by the United Nations to ensure sustainable resource usage and the acceleration of sustainable and green construction practices.
... Khondoker [11] employed market-length rebar to reduce rebar cutting waste in RC frames, leading to a rebar cutting waste of 2.69%. Zheng et al. [16] attempted to minimize slab rebar cutting waste by using market-length rebar, resulting in 14.49% cutting waste. Considering the near-zero cutting waste strategy (N0RCW), the outcomes obtained in these studies remain noticeably high. ...
... Additional top rebar itself themselves can be distinguished into two categories: additional top rebar for the end support and additional top rebar for the mid support. The previous study introduced a precise calculation approach, presented in Equations (14)- (16), for accurately calculating the length of additional rebar [36]. The additional top rebar for both end supports (L; mm) can be calculated using Equation (14) considering the hook anchorage length (l anchor−t ), the beam's clear span length (L csi ; mm), the additional embedded length (l a ; mm), the column width at either the left or right-support end (W i ; mm), and the rebar bending deduction (b margin ): ...
... The additional bottom rebar for the middle span (L; mm) can be acquired utilizing Equation (16) considering the beam's clear span length (L csi ; mm) and additional embedded length (l a ; mm): ...
Article
Full-text available
While various approaches have been developed to minimize rebar cutting waste, such as optimizing cutting patterns and the lap splice position, reducing rebar usage by minimizing the number of splices remains uninvestigated. In response to these issues, a two-stage optimization algorithm was developed that prioritizes the use of special-length rebar to achieve a near-zero rebar cutting waste (N0RCW) of less than 1%, while also reducing overall rebar usage. The two-stage algorithm first optimizes the lap splice position for continuous rebar considering the use of a special-length rebar, which reduces the number of splices required. It then integrates a special-length minimization algorithm to combine the additional rebar. The algorithm was applied to beam structures in a small-sized factory building project, and it resulted in a notable reduction of 29.624 tons of rebar, equivalent to 12.31% of the total purchased quantity. Greenhouse gas emissions were reduced by 102.68 tons, and associated costs decreased by USD 30,256. A rebar cutting waste of 0.93%, which is near zero, was achieved. These findings highlight the significant potential of the proposed algorithm for reducing rebar waste and facilitating sustainable construction practices. The algorithm is also applicable to other reinforced concrete projects, where the associated advantages will be amplified accordingly.
... Numerous studies on the optimization of rebar-cutting waste have been conducted to this time. Most studies emphasize the utilization of stock length or market length to make a combination that diminishes cutting waste [8,10,[12][13][14]. In their study, Porwal and Hewage [15] introduce the concept of special-length combination to optimize rebar-cutting waste and obtain favorable outcomes. ...
... Khondoker [7] employed the market-length rebar to reduce rebar-cutting waste in RC frames, leading to 2.69% of rebar-cutting waste. Zheng et al. [12] attempt to minimize slab rebar-cutting waste by using market-length rebar, resulting in 14.49% cutting waste. Considering the near-zero cutting waste strategy, the outcomes obtained in these studies remain noticeably high. ...
... Rebar details and arrangement of the G12 beam.12 ...
Preprint
Full-text available
The extensive utilization of rebar during the construction of the project generates immense rebar waste, leading to increased construction costs and significant greenhouse gas emissions. Various approaches have been explored focusing on the minimization of rebar-cutting waste, such as optimizing cutting patterns, lap splice position, and special-length rebar utilization. Nonetheless, reducing rebar usage by minimizing the number of splices remains uninvestigated. In response to these issues, a two-stage optimization algorithm was developed, prioritizing special-length rebar to achieve near-zero rebar-cutting waste of less than 1% and concurrently reduce rebar usage, thereby promoting sustainable construction practices. The two-stage algorithm presented in this study involves the optimization of the lap splice position for the continuous rebar with a reduction of splices number. Furthermore, it integrates a special-length minimization algorithm for the additional rebars. Applying the algorithm to beam structures in a small-sized factory building project led to a notable reduction of 29.624 tons of rebar, equivalent to 12.31% of the total purchased quantity. Greenhouse gas emissions were reduced by 102.68 tons, and associated costs decreased by USD 30,256. A rebar-cutting waste of 0.99% which is near zero was achieved. These findings highlight the significant potential of the proposed algorithm in reducing rebar waste and facilitating sustainable construction practices. In addition, the application of the proposed algorithm in reinforced concrete construction projects will amplify the associated advantages accordingly.
... As shown in Table 1, in some studies [13][14][15][26][27][28][29], the cutting patterns were optimized to minimize cutting waste, while in other studies [11,12,30], cutting waste was reduced by optimizing lap splice position using stock length. However, they did not achieve significant reduction, as they adhered to building code regulations for lap splice position and only utilized stock length. ...
... [ [13][14][15][26][27][28][29] Lap splice position optimization with adherence to lap splice position regulation using stock-length rebar -Reduced cutting waste was achieved while maintaining compliance with splicing regulations for rebar. -Method was applied to beam, column, and shear walls. ...
Article
Full-text available
The production of steel rebar is an energy-intensive process that generates CO2 emissions. In construction, waste is generated by cutting stock-length rebar to the required lengths. The reduction rate achieved in most previous studies was limited due to adherence to lap splice positions mandated by building codes and the use of stock-length rebar. A previous study demonstrated a significant reduction in rebar usage and cutting waste, approaching zero, upon optimizing the lap splice position, reducing the number of splices, and utilizing special-length rebar. However, the reference length used to determine the special-length rebar was not clearly optimized. This study proposes a special length priority optimization model to minimize wall rebar usage and waste by reducing the number of splices while simultaneously ensuring an optimal reference length. The proposed model was validated using a case study wall with a standard hook anchorage at the top of the wall reinforcement. The optimization model reduced rebar cutting waste to 0.18% and decreased rebar usage from the original design by 16.16%.
... Also, the difference between the optimized and unoptimized elastic design shows negligible differences in steel volume and hence in the embodied carbon. This is opposite to the emphasis previous studies gave to the role of optimized detailing of steel reinforcement as a low carbon strategy [56]. The error bars in Fig. 8 represents the differences between average quantities obtained by YLM method and the corresponding maximal/minimal average from optimized and unoptimized LEFEA. ...
Article
Full-text available
binders. For each scenario, material quantities are calculated following design prescriptions by EN1992-1-1 while state-of-the art life cycle inventory data are adopted to calculate the carbon footprint. Results show that shifting towards more efficient structural systems (i.e., waffle slab system) could save up to 20% of the carbon footprint on the building level compared to more traditional systems, such as slab on beams and flat slabs. In addition, reducing the spans from 7.5 to 5 m can save up to 20% more. Finally, the use of low-clinker cement in low-binder concrete can save another 50% in terms of CO 2 impact per built-up area. Realistically, results of the case study concluded that implementing these three strategies could reduce the typical 232 kg CO 2 e/m 2 value of the carbon footprint of structural elements of a mid-rise building up to only 58 kg CO 2 e/m 2 , i.e., a four-fold reduction. Abstract Mid-rise reinforced concrete buildings are projected to continue being the predominant typology for urban development. Thus, reducing the carbon footprint of such buildings is critical for achieving a sustainable built environment. Reducing the amount of concrete and steel in a building through structural and mix design optimization is identified as a primary resource efficiency strategy. This paper is among the first to present evidence of the decarbonization potential of these dematerialization strategies on a building level. The study combines structural design choices such as slab system design, steel reinforcement optimization and span width with materials-based strategies , such as low binder concrete and low-carbon Supplementary Information The online version contains supplementary material available at https:// doi.
... Stock-length rebar refers to the specific standardized lengths of rebars provided by steelworks [21]. Unfortunately, these endeavors [6,7,[21][22][23][24][25] continue to generate large amounts of cutting waste. Several researchers have also incorporated lap-splice position optimization [6,7] following building codes; however, this still resulted in significant cutting waste. ...
Article
Full-text available
The surging demand for reinforced concrete buildings has led to excessive consumption of rebars, resulting in substantial rebar-cutting waste and greenhouse gas emissions. Various approaches have been explored to mitigate this issue, including lap-splice optimization and the use of special-length rebars without adhering to lapping zone rules. However, these methods do not adequately address rebar overconsumption. Conventional lap splicing is associated with several drawbacks, such as excessive rebar consumption and structural integrity concerns. Therefore, mechanical couplers have emerged as promising alternatives to address these limitations. This study assessed the impact of a combined coupler and special-length-priority optimization algorithm on reducing rebar consumption and cutting waste in beams, with the aim of achieving near-zero cutting waste. The proposed algorithm was then applied to the reinforcement of beams in a high-rise building, and a significant reduction in ordered rebar consumption was achieved, reaching 17.28 % and 5.66 %, respectively, compared with the original design and a previous study. This reduction consequently lowered greenhouse gas emissions by 14.52 % and 2.51 % compared with the original design and previous study, respectively. Additionally, 12.98 % and 0.57% reductions in the total cost were achieved compared with the original design and previous study, respectively. The results of this study offer a novel perspective for the industry to further minimize rebar consumption and its associated sustainability implications without compromising structural integrity.
... Also, the difference between the optimized and unoptimized elastic design shows negligible differences in steel volume and hence in the embodied carbon. This is opposite to the emphasis previous studies gave to the role of optimized detailing of steel reinforcement as a low carbon strategy [52]. The error bars in Fig. 6 represents the differences between average quantities obtained by YLM method and the corresponding maximal/minimal average from optimized and unoptimized LEFEA. ...
Preprint
Full-text available
Mid-rise reinforced concrete buildings are projected to continue being the predominant typology for urban development. Thus, reducing the carbon footprint of such buildings is critical for achieving a sustainable built environment. Reducing the amount of concrete and steel in a building through structural and mix design optimization is identified as a primary resource efficiency strategy. This paper is among the first to present evidence of the decarbonization potential of these dematerialization strategies on a building level. The study combines structural design choices such as slab system design, steel reinforcement optimization and span width with materials-based strategies, such as low binder concrete and low-carbon binders. For each scenario, material quantities are calculated following design prescriptions by EN1992-1-1 while state-of-the art life cycle inventory data are adopted to calculate the carbon footprint. Results show that shifting towards more efficient structural systems (i.e., waffle slab system) could save up to 20% of the carbon footprint on the building level compared to more traditional systems, such as slab on beams and flat slabs. In addition, reducing the spans from 7.5 to 5 m can save up to 20% more. Finally, the use of low-clinker cement in low-binder concrete can save another 50% in terms of CO 2 impact per built-up area. Realistically, results of the case study concluded that implementing these three strategies could reduce the typical 232 kg CO 2 e/m ² value of the carbon footprint of structural elements of a mid-rise building up to only 58 kg CO 2 e/m ² , i.e., a four-fold reduction.
... Khalifa et al. [22] N/A 5.15% Khondoker [23] RC frames 2.69% Zheng et al. [24] RC slab 14.49% Zheng et al. [25] RC slab 1.8% Chen and Yang [7] RC beam section 8.4% ...
Article
Full-text available
The construction of reinforced concrete (RC) structures inevitably consumes an excessive number of rebars, leading to significant cutting waste and carbon emissions. Extensive research has been conducted to minimize this issue and its consequences; however, these methods consistently consume a substantial number of rebars. This includes a previous study that utilizes the lap splice position optimization and special-length rebar concept without considering the lapping zone regulation. Moreover, conventional lap splices pose inherent drawbacks that could jeopardize the structural integrity of RC members. In contrast, mechanical couplers eliminate the need for rebar lapping, effectively reducing rebar consumption. This research aims to evaluate the impact of an integrated mechanical coupler and special-length-priority minimization algorithm on the reduction in rebar consumption and cutting waste in RC columns, achieving near-zero cutting waste. To validate the effectiveness of the proposed algorithm, it was applied to the column rebars of an RC building. The results revealed a significant reduction in the ordered rebar consumption by 18.25%, accompanied by substantial reductions in the cutting waste (8.93%), carbon emissions (12.99%), and total costs (9.94%) compared with a previous study. The outcomes provide the industry with insights into further reducing rebar consumption and its related consequences. Applying the proposed algorithm to various construction projects will further amplify the corresponding benefits.
... The concept of flexibility in the length of rebars for specific structural elements enables decision makers to achieve more efficient material utilization during the process of generating cutting patterns. Zheng and Lu (2016) considered rebar material costs related to trim loss and rebar installation costs including labor hours used in rebar stock processing, delivering, placing, and tying. Benjaoran et al. (2019) studied the effect of demand variations on steel bars cutting loss and experimentally showed how the distribution of pieces of length ordered affects material utilization. ...
Article
This paper presents a comprehensive comparison between conventional reinforced concrete (RC) and steel fiber‐reinforced concrete (SFRC) slabs. Twenty‐two‐way rectangular RC and SFRC slabs are designed with varying dimensions, aspect ratios, and boundary conditions, following verified international standards to compare the steel quantities in a unique study. SFRC slabs with larger aspect ratios and discontinuous edges required significantly higher steel percentages than square slabs, as the random three‐dimensional distribution of steel fibers suited the load distribution pattern of square slabs. To further conduct a detailed design and economic feasibility case study on a realistic building model, two 12‐story buildings are computationally designed with RC and SFRC alternatives. The results indicate that SFRC slabs required approximately 25% more steel than RC slabs due to the uniform distribution of steel fibers throughout the section. Project cost and time estimates were conducted based on standard productivity manuals and cost databases in two distinct economies, India and the USA. Despite the higher steel requirements, the 12‐story SFRC building showed time savings of 34.1 days (5.44%) and cost savings of 4.88% and 1.27% when constructed in the USA and India, respectively. The results are compared with limited available data in literature. In conclusion, the study suggests that SFRC slabs in multi‐story buildings could be more economically favorable in countries with higher labor costs.
Article
Full-text available
Loss of rebars can be minimized with minimum use of discrete bars in market length. In order to achieve this goal, the accurate and detailed information of rebars is extracted, followed by both rapid and efficient bar combination. No paper has dealt directly with the reduction of rebar waste rates, although many researches have proposed indirect approaches to enhance productivity, constructability, safety and quality in the process of concrete reinforcement work. This paper, therefore, was prepared with the aim of developing algorithms to supply rebars required to minimize material waste during cutting and bending of discrete bars in rebar shops. At the same time, this study presented an automatic rebar detailing concept, a logical process of rebar combination with pertinent algorithms and binary search algorithm for bar data to implement the proposed topic. The effectiveness of the suggested algorithms was validated by case studies.
Article
Full-text available
The cutting-stock problem is the problem of filling an order at minimum cost for specified numbers of lengths of material to be cut from given stock lengths of given cost. When expressed as an integer programming problem the large number of variables involved generally makes computation infeasible. This same difficulty persists when only an approximate solution is being sought by linear programming. In this paper, a technique is described for overcoming the difficulty in the linear programming formulation of the problem. The technique enables one to compute always with a matrix which has no more columns than it has rows.
Article
Full-text available
A CAD/CAM system that automates the design and manufacturing of rebars is described. The CAD-based design module of the system permits a semiautomated design alongside the conventional one. The uniqueness of the system resides in its ability to extract automatically the data needed for manufacturing from the graphic design database, process these data, and transfer them to the rebar-manufacturing machine. Thus all the manual data manipulation stages of traditional rebar design and production (detailing, documentation, data extraction, etc.) are avoided. In many cases the multistage manual data manipulation is a source of errors and is moreover labor-intensive. Consequently, the CAD/CAM system described here leads to cost reduction together with increased quality. This paper describes the principles underlying the development of the system and the system's structure, which is based on a design module, a data extraction module, and a data processing and transfer module.
Article
Full-text available
This paper is about the solution of certain classes of the cutting stock problem to optimality. The work is based on enumerating the possible cutting patterns, and solving the associated integer program by a combination of cutting planes and branch and bound. The resulting program was initially implemented in February 1985 for a one-dimensional cutting stock problem in a large board mill in the UK, where it has generated average savings of 2.5% of production compared to the best of two previous computer programs. The solutions obtained by the program are usually optimal in trim loss terms. Subsequent, post-solution optimisation minimises cutting patterns and reduces knife setups.
Article
Construction process activities are very complex in nature and there have been attempts to simulate them via numerous methods. Manual work, which constitutes a large proportion of total construction in India and developing countries, requires emphasis. Field data-based mathematical simulations develop an empirical relation between inputs and outputs; once the model is developed and weaknesses have been identified, methods can be easily improved and optimised for output goals. This paper covers in detail the process of developing models for the rebar cutting subactivity of reinforced concrete construction in residential buildings. These models are evaluated using sensitivity analysis, optimisation techniques and reliability analysis and are validated using artificial neural networks.
Article
Building information modeling (BIM) is an emerging tool in architecture/engineering/construction (A/E/C) industry that is used to design, document, and enhance communication among all the project stakeholders. Trim loss of rebar can be minimized with the use of discrete bars. To achieve this goal, a model to analyze reinforced concrete structure with one-dimensional (1D) cutting waste-optimization technique, integrated with BIM, is proposed. Building information modeling is selected as the hub in communicating project information among diverse design teams. This process permits project teams to utilize BIM models to simulate architectural and structural design requirements, and compare results speedily to make necessary changes in the designs to minimize rebar waste. The BIM rebar optimization analysis approach also supports cost-effective decision making during the design process. The proposed approach was validated with a two-story reinforced concrete structure, and the results indicated a high potential for budgetary savings. The proposed approach is also applicable for complex reinforced concrete construction projects, with repeated structural elements, and cost saving increases with the increase in the diameter of rebar. DOI: 10.1061/(ASCE)CO.1943-7862.0000508. (C) 2012 American Society of Civil Engineers.
Article
The limited availability of reconstruction resources is one of the main challenges that often confront postdisaster recovery of damaged transportation networks. This requires an effective and efficient deployment and utilization of these limited resources in order to minimize both the performance loss of the damaged transportation network and the reconstruction costs. This paper presents the development of a robust model for planning postdisaster reconstruction efforts that is capable of: (1) optimizing the allocation of limited reconstruction resources to competing recovery projects; (2) assessing and quantifying the overall functional loss of damaged transportation networks during the recovery efforts; (3) evaluating the impact of limited availability of resources on the reconstruction costs; and (4) minimizing the performance loss of transportation networks and reconstruction costs. The model utilizes the user equilibrium algorithm to enable the assessment of the transportation network performance losses and a multiobjective genetic algorithm to enable the generation of optimal tradeoffs between the two recovery planning objectives. An application example is analyzed to demonstrate the use and capabilities of the recovery planning model.
Article
Materials that are in the form of one-dimensional stocks such as steel rebars, structural steel sections, and dimensional lumber generate a major fraction of the generated construction waste. Cutting one-dimensional stocks to suit the construction project requirements result in trim or cutting losses, which is the major cause of the one-dimensional construction waste. The optimization problem of minimizing the trim losses is known as the cutting stock problem (CSP). In this paper, three approaches for solving the one-dimensional cutting stock problem are presented. A genetic algorithm (GA) model, a linear programming (LP) model, and an integer programming (IP) model were developed to solve the one-dimensional CSP. Three real life case studies from a steel workshop have been studied. The generated cutting schedules using the GA, LP, and IP approaches are presented and compared to the actual workshop's cutting schedules. The comparison shows a high potential of savings that could be achieved using such techniques. Additionally, a user friendly Visual Basic computer program that utilizes genetic algorithms for solving the one-dimensional CSP is presented.
Article
In the United States, vast amounts of construction waste are produced every year. Construction waste accounts for a significant portion of the municipal waste stream of the United States. One-dimensional stocks are one of the major contributors to construction waste. Cutting one-dimensional stocks to suit needed project lengths results in trim losses, which are the main causes of one-dimensional stock waste. Although part of such waste is recyclable such as steel waste, reduction in the generation of waste can enhance the stock material usage and thereby increase the profit potential of the company. The traditional optimization techniques (i.e., linear programming and integer programming) suffer some drawbacks when they are used to solve the one-dimensional cutting stock problem (CSP). In this paper, a genetic algorithm (GA) model for solving the one-dimensional CSP (GA1D) is presented. Three real life case studies from a local steel workshop in Fargo, North Dakota have been studied, and their solutions (cutting schedules) using the GA approach are presented and compared with the actual workshop cutting schedules. The comparison shows a high potential of savings that could be achieved.Key words: construction waste management, waste reduction, genetic algorithm, GA, cutting stock problem, CSP, optimization, reinforcement steel optimization, rebar optimization.
Article
This paper describes a real feasibility study of applying large-scale optimization methods to the cutting stock problem of irregular shapes. We identify two approaches for minimizing waste in the cutting stock problem of irregular shapes: better packing and better scheduling of cuts. This paper is concerned with the scheduling problem only. By scheduling of cuts we mean deciding which combination of parts to group together on the cutting table so that overall material needed by all cuts is minimized. Such a problem usually requires considering many combinations. However, with the development of various feasibility requirements imposed on the column generation process this number can be reduced considerably. Furthermore, the introduction of interior-point algorithms for linear programming by Karmarkar in 1984, allows the consideration of much larger linear programming problems than was possible just a few years ago.