Quantifying Rework Propagation Between Sequential Construction Stages: A Stage-Based Analytical Framework

Rework propagation significantly impacts construction quality, cost performance, and project predictability. However, the mechanism by which geometric deviations amplify across sequential construction stages remains insufficiently modeled. This study introduces the stage-based rework propagation model (SRPM), a practical analytical framework designed to quantify deviation growth through dependency-weighted propagation coefficients. Two representative scenarios—structural and architectural sequences—were examined using real project inspection data. Results demonstrate that structural deviations exhibit substantial amplification (Pc values between 2.3 and 4.1), whereas architectural deviations remain comparatively contained (Pc values between 1.1 and 1.6). These findings confirm the disproportionate influence of early structural accuracy on downstream quality performance. SRPM offers a decision-support tool for QA/QC professionals, enabling risk-based inspection planning, rational tolerance decisions, and early corrective interventions. The framework provides both theoretical advancement and practical applicability for minimizing cumulative rework in construction projects. This manuscript is a preprint version of a paper currently under peer review at the Journal of Engineering, Project, and Production Management (JEP2M). The preprint is shared for academic discussion and early dissemination of research findings.