Simulation-Based Optimization of Crane Lifting Position and Capacity Using a Construction Digital Twin for Prefabricated Bridge Deck Assembly

The growing adoption of off-site construction methods has increased the critical role of mobile cranes within the construction sector. This study develops a Construction Digital Twin (CDT) framework to optimize crane lifting positions and capacities for the installation of prefabricated bridge decks. By integrating 3D site modeling, Building Information Modeling (BIM), and crane simulations within the Unity game engine, the CDT overcomes the limitations of conventional 2D-based planning by providing a three-dimensional representation of site conditions. An exhaustive search method identifies optimal crane configurations, enhancing precision and efficiency. Simulation calibration using video analysis of real bridge deck installations aligns crane speed and cycle times with actual operations, improving reliability. Case studies demonstrate the CDT’s ability to reduce crane operation costs by 27% when employing a smaller capacity crane while maintaining operational efficiency. Additional DFA-focused simulations with varying deck dimensions revealed a potential 10% cost reduction by optimizing crane operations and deck design strategies. The CDT framework supports early-stage planning, reduces operational risks, and contributes to cost-effective and safer construction practices, offering a scalable solution adaptable to various construction scenarios.