Application of a Design Method for Manufacture and Assembly Flexible Assembly Methods and their Evaluation for the Construction of Bridges Master of Science Thesis in the Master’s Programme Design and Construction Project Management MICHEL KALYUN TEZERA WODAJO Department of Civil and Environmental Engineering Division of Structural Engineering Steel and Timber Structures CHALMERS UNIVERSITY OF TECHNOLOGY Göteborg, Sweden 2012 Master’s Thesis 2012:29 MASTER’S THESIS 2012:29 Application of a Design Method for Manufacture and Assembly Master of Science Thesis in the Master’s Programme Design and Construction Project Management MICHEL KALYUN & TEZERA WODAJO Department of Civil and Environmental Engineering Division of Structural Engineering Steel and Timber Structures CHALMERS UNIVERSITY OF TECHNOLOGY Göteborg, Sweden 2012 Application of a Design Method for Manufacture and Assembly Flexible Assembly Methods and their Evaluation for the Construction of Bridges Master of Science Thesis in the Master’s Programme Design and Construction Project Management MICHEL KALYUN & TEZERA WODAJO © MICHEL KALYUN & TEZERA WODAJO, 2012 Examensarbete/Institutionen för bygg- och miljöteknik, Chalmers tekniska högskola 2012:29 Department of Civil and Environmental Engineering Division of Construction Management Chalmers University of Technology SE-412 96 Göteborg Sweden Telephone: + 46 (0)31-772 1000 Cover: Demonstration of easy assembly Chalmers reproservice / Department of Civil and Environmental Engineering Göteborg, Sweden 2012 Application of a Design Method for Manufacture and Assembly Flexible Assembly Methods and their Evaluation for the Construction of Bridges Flexible Assembly Methods and their Evaluation for the Construction of Bridges Master of Science Thesis in the Master’s Programme Design and Construction Project Management MICHEL KALYUN & TEZERA WODAJO Department of Civil and Environmental Engineering Division of Construction Management Chalmers University of Technology ABSTRACT The core of this thesis work is formulated by tasks of identification, rationalization and evaluation of technical solutions, bridge concepts and assembly methods being used in other sectors. The concept of Design for Manufacturing and Assembly (DFMA) will be applied for the evaluation of these flexible assembly techniques and bridge concepts. In order for this to happen, this paper primarily lays a theoretical background of the concept of DFMA and criteria that need to be fulfilled in the successful implementation of the system. These DFMA requirements are further processed together with parameters that are bridge specific for realization of a more consolidated set of general DFMA criteria that are adaptive to the construction and/or installation of bridges. The general DFMA criteria are then studied from a manufacturing and assembly perspective which yields characteristics that belong to each block. By tracing the properties of the said manufacturing and assembly characteristics, goals set by project PANTURA are expressed in terms of their respective manufacturing and assembly characteristics. The criteria prescribed under each PANTURA indicators are then utilized as basis for qualitative evaluation of assembly methods and bridge technical concepts, presentation of which form part of the research work. Evaluation of each assembly techniques and bridge concepts has been done according to the extent to which they fulfil the PANTURA goals. During the course of the work certain difficulties that are inherent in the nature of the construction industry and context of the work are also traced and remarks are made on them. Further studies on this topic can be conducted by limiting the subject according to parties involved in the overall construction process and/or work methodologies that are followed on-site. Key words: design decision support tools, design methods, bridge construction, industrial thinking, Design for Manufacturing and Assembly, criteria, knowledge transfer, evaluation, PANTURA indicators I Applicering av Design Metod för Tillverkning och Montering Flexibla monteringsmetoder och deras utvärdering för brobyggande Examensarbete inom Design and Construction Project Management MICHEL KALYUN & TEZERA WODAJO Institutionen för bygg- och miljöteknik Avdelningen för Construction Management Chalmers tekniska högskola SAMMANFATTNING Kärnan av detta examensarbete består utav uppgiftsidentifiering, rationalisering och utvärdering av tekniska koncept, brokoncept och monteringsmetoder brukade i andra industrier. Konceptet Design for Manufacturing and Assembly (DFMA) kommer att tillämpas för utvärdering av dessa flexibla monteringstekniker och brokoncept. För att göra detta genomförbart, kommer det i första hand ett utlägg av den teoretiska bakgrunden för begreppet DFMA att genomföras och de kriterier som krävs för en lyckad applicering av systemet. Dessa kriterier kommer att tillsammans med parametrar specifika för brokonstruktion att bearbetas och genomgå en förverkligandet av en ny uppsättning generella DFMA kriterier som är anpassade till byggande och/eller uppförande av broar. De generella DFMA kriterierna är därefter studerade ur tillverkning- och monteringsaspekter för att i enlighet med deras egenskaper delas upp i de två perspektiven. Genom att spåra egenskaperna för tillverkning- och monteringskaraktärer, kan de vidare användas vid tilldelning för de indikatorer som projektet PANTURA har satt upp i enlighet med deras uppsatta mål. De kriterier som föreskrivs under varje PANTURA indikator används sedan som underlag för kvalitativ utvärdering av monteringsmetoder och brotekniska koncept, en presentation som är del av detta arbete. Utvärderingen av varje monteringsteknik och brokoncept har gjorts i enlighet med den utsträckning som uppfyller PANTURA målen. Under arbetets gång har vissa svårigheter naturliga till byggindustrin och omfattningen av arbetet uppdagats, vidare uppmärksammats och kommenterats. Fortsatta studier inom temat kan utföras genom att begränsa ämnet efter parter involverade i den övergripande byggprocessen och/eller de arbetsmetoder som följs på byggarbetsplatserna. Nyckelord: beslutsverktyg för konstruktioner, design metoder, brokonstruktioner, industriellt tänkande, Design for Manufacturing and Assembly, montering, kriterier, kunskapsöverföring, utvärdering, PANTURA indikatorer II Contents 1 INTRODUCTION 1 1.1 PANTURA project 1 1.2 Concurrent Engineering, Lean Manufacturing and Design decision support tools 2 1.3 Background 4 1.4 Purpose and objectives 4 1.5 Method 4 1.6 Scope and limitations 5 2 THE CONCEPT OF DESIGN FOR MANUFACTURING AND ASSEMBLY (DFMA) 7 2.1 Defining DFMA 7 2.2 Why DFMA – benefits and challenges 11 2.2.1 Benefits 12 2.2.2 Challenges 14 2.3 DFMA: state of the art in various industries 14 2.3.1 DFMA and advanced manufacturing technologies 15 2.3.2 Application of DFMA in different industries 17 2.4 General DFMA criteria 19 2.5 DFMA: state of the art in the construction industry 22 3 DFMA CRITERIA AND PANTURA INDICATORS 27 3.1 PANTURA indicators in bridge construction 27 3.2 DFMA translation of PANTURA indicators 27 3.2.1 Characterization of the general DFMA criteria 28 3.2.2 Translation of the PANTURA indicators 30 a. Mobility 31 b. Lifecycle cost 32 c. Time 35 d. Worker safety during construction 38 e. Safety of residents 41 f. Noise disturbance 42 g. Dust emissions 43 h. Greenhouse gas (GHG) emissions 44 i. Energy use 46 j. Waste reduction/recycling 47 4 REVIEW OF INDUSTRIALIZED ASSEMBLY METHODS 51 4.1 ConXtech structural steel space frame systems 51 4.1.1 On-site assembly techniques for composite FRP-steel bridges 54 CHALMERS Civil and Environmental Engineering, Master’s Thesis 2012:29 III a. Technical concept 1: Snap-fit connection between FRP deck and steel girders 54 b. Technical concept 2: Bolted connection between FRP deck and steel girders 55 c. Technical concept 3: Shear-stud connection between FRP deck and steel girders 56 d. Technical concept 4: Bar-and-slot and snap-fit connections between FRP deck panels 57 5 EVALUATION METHODS 59 5.1 Approach and choice of evaluation method 59 5.1.1 The approach 59 5.1.2 Choice of evaluation method 61 5.2 Qualitative methods of evaluation for manufacturing and assembly 63 5.3 Assignment of weights and value engineering 64 5.4 The evaluation and interpretation of results 66 6 DISCUSSION 70 7 CONCLUSION 74 8 REFERENCES 75 APPENDIX A: COMMENTS ON THE WEIGHTING 1 a. Mobility 1 b. Lifecycle Cost 1 c. Time 2 d. Worker Safety 3 e. Safety of residents 4 f. Noise disturbance 5 g. Dust emissions 5 h. Greenhouse gas 6 i. Energy use 6 j. Waste reduction/recycling 7 CHALMERS, Civil and Environmental Engineering, Master’s Thesis 2012:29 IV CHALMERS Civil and Environmental Engineering, Master’s Thesis 2012:29 V Preface This master’s project is conducted in partial fulfilment of the requirements for a master’s degree in Design and Construction Project Management and was carried out in the department of Structural Engineering at Chalmers University of Technology, Sweden, in collaboration with NCC Teknik, Sweden. The period of the research lasted from January 2012 until July 2012. Primarily, we would like to thank our supervisors Mohammad Al-Emrani (Associate professor) and Valbona Mara (Ph.D. student) at Chalmers University of Technology, for their valuable inspiration and support during the course of the research. We also would like to forward our gratitude to Christina Claesson-Jonsson, Alexandre Mathern and Tobias Larsson from NCC Teknik for all the help and encouragement they provided