Scan-to-BIM approach for enhanced semi-automated cost management in modular off-site construction

Purpose This research integrates lean construction principles with scan-to–building information modeling (BIM) to enhance cost management in modular off-site construction. It proposes a scan-to-BIM approach within a semi-automated 5D-BIM framework to improve cost estimation accuracy and efficiency. By leveraging 3D laser scanning, it enhances quantity takeoff and cost reporting, reducing manual errors and improving decision-making during manufacturing and in-factory assembly. Design/methodology/approach A design science research methodology is used to compare the proposed lean-driven 5D-BIM framework with traditional cost management practices. The integration of 3D laser scanning and scan-to-BIM improves measurement accuracy and automates data extraction and analysis. Lean construction reduces waste and maximizes value through collaboration, while modular off-site construction benefits from prefabrication in controlled environments. The 5D-BIM model embeds cost data, enabling more precise quantity takeoffs. In contrast, traditional cost management remains heavily manual and less efficient. Findings The proposed approach reduces the time required for progress cost reporting by 18% and improves cost estimation accuracy by 12%, highlighting the value of combining lean principles with advanced BIM technologies. Research limitations/implications The study is limited to the manufacturing and assembly phases of modular off-site construction in Canada. Results may vary when applied to other phases or regions. Practical implications The framework offers actionable guidance for industry professionals aiming to improve cost control, data accuracy and resource planning in modular off-site projects, while advancing the human-centered transformation of the architecture, engineering, construction and operation industry by automating repetitive tasks, enhancing collaboration and enabling professionals to focus on higher-value decision-making. Originality/value This study uniquely combines lean construction, scan-to-BIM and 5D-BIM to tackle cost management challenges, promoting efficiency, accuracy and digital innovation in off-site construction.