On-Site Comprehensive Surface Quality Assessment of Prefabricated Composite Slabs Based on Colored Point Clouds

The increasing prevalence of prefabricated buildings in the modern construction industry has accentuated the necessity for rigorous and precise geometric inspections of factory-produced components. Traditional inspection methods, which are heavily reliant on manual labor and human oversight, are often time-consuming, labor-intensive, and ultimately ineffective, particularly when dealing with complex structural elements such as composite slabs. Recognizing these challenges, this study introduces an innovative assessment method that synergizes state-of-the-art point cloud processing with advanced image processing techniques. This integrated approach is designed to simultaneously evaluate surface flatness and systematically identify various defects in prefabricated composite slabs. The methodology encompasses five key steps: the acquisition of high-resolution colored point clouds, precise segmentation of composite slabs, detailed analysis of global flatness deviations, localized detection of multiple surface defects, and a comprehensive surface quality assessment. To validate the proposed approach, a real-world case study was meticulously executed, showcasing the method’s efficacy in utilizing point cloud data and RGB information for accurate flatness analysis and defect identification. We ultimately obtained comprehensive detection results for slab surface flatness and localized defects, which were found to be consistent with real-world engineering applications. These findings demonstrate that the integrated geometric surface inspection methodology is both highly efficient and remarkably effective in significantly enhancing the quality control processes for prefabricated composite slabs. This research has broader implications beyond traditional manual inspection methods. It lays the foundation for enhancing construction efficiency, reducing the resources allocated to detecting surface defects, and decreasing project delays and costs that are often caused by insufficient prefabrication quality.