Determining different levels of modularization on a construction project through a product architecture modularity decomposition approach – a case study

Purpose Modular integrated construction is a construction industrialization approach which arises as an alternative to traditional methods and has a substantial impact on the design, development and management of construction projects. This study aims to improve the design process in modular integrated construction through the identification and analysis of different levels of construction modularization. To do so, a modularity decomposition approach to product architecture is applied Design/methodology/approach This study uses a hybrid method that combines hierarchical clustering (cladistics) with a design structure matrix for determining the optimal granularity level for the product architecture and generating modules with the minimum external interfaces and maximum internal integration. The proposed method is validated through a case study, conducted on a three-dimensional prefabricated structure comprising a kitchenette and toilet unit meant for university residence rooms. Findings The application of the proposed approach in the construction case study effectively identified the ideal granularity level on which an objective definition of various modularization levels may be established. The results demonstrate the potential of the technique to identify viable product and process platforms and suggest that the approach is capable of guiding modular design decisions and improving integration in construction projects. Originality/value This research introduces a novel application of a previously researched modularity decomposition technique – originally developed for the automotive industry – to the industrialized construction sector as a structured and objective method for determining different levels of construction modularization. The findings indicate its potential to analyze increasingly complex building units and advancing construction industrialization efforts.