Defects in Modular Building Construction: A Systematic Lifecycle Review and Implications for Sustainable Delivery

Despite its potential to enhance construction quality, efficiency, and sustainability, modular construction continues to experience defects that hinder its broader adoption. Understanding and mitigating defects is essential for maximising the sustainability benefits of modular construction by reducing material waste, minimising rework and improving lifecycle performance. Existing research remains fragmented, with limited synthesis integrating defects with their root causes across the project lifecycle. To address this gap, this study investigates defect types, lifecycle-based causes, and mitigation strategies in modular building projects through a PRISMA-guided systematic literature review of 61 peer-reviewed journal articles published between 2015 and 2025 and retrieved from Scopus and Web of Science. Six major defect categories were identified: geometric and dimensional; material and component; joint and connection integrity; envelope performance and durability; structural; and mechanical, electrical, and plumbing (MEP) defects, with geometric and dimensional defects emerging as the most prevalent, accounting for 26.7% of reported cases. Lifecycle root-cause mapping indicates that poor workmanship during on-site assembly is the dominant contributor, accounting for 44.1% of identified root causes, with manufacturing errors (26.8%) and design limitations (13.4%) acting as critical upstream sources. Mitigation strategies cluster into three groups: general recommendations (39% of reported strategies), mainly focusing on low-cost organisational measures such as logistics coordination and workforce training; structured risk-management frameworks (9.1%), including assembly sequencing and tolerance planning; and digital and data-driven technologies (51.9%), such as laser scanning, AI-based inspection, and digital twins, enabling proactive quality assurance across the lifecycle. The study proposes an integrated lifecycle–defect–mitigation framework to strengthen quality governance and advance sustainable modular delivery.