Drywall Installation Research Articles

Enabling Building Information Model-driven human-robot collaborative construction workflows with closed-loop digital twins

The introduction of assistive construction robots can significantly alleviate physical demands on construction workers while enhancing both the productivity and safety of construction projects. Leveraging a Building Information Model (BIM) offers a natural and promising approach to driving robotic construction workflows. However, because of uncertainties inherent in construction sites, such as discrepancies between the as-designed and as-built components, robots cannot solely rely on a BIM to plan and perform field construction work. Human workers are adept at improvising alternative plans with their creativity and experience and thus can assist robots in overcoming uncertainties and performing construction work successfully. In such scenarios, it is critical to continuously update the BIM as work processes unfold so that it includes as-built information for the ensuing construction and maintenance tasks. This research introduces an interactive closed-loop digital twin framework that integrates a BIM into human-robot collaborative construction workflows. The robot’s functions are primarily driven by the BIM, but it adaptively adjusts its plans based on actual site conditions, while the human co-worker oversees and supervises the process. When necessary, the human co-worker intervenes in the robot’s plan by changing the task sequence or workspace geometry or requesting a new motion plan to help the robot overcome the encountered uncertainties. A drywall installation case study is conducted to verify the proposed workflow. In addition, experiments are carried out to evaluate the system performance using an industrial robotic arm in a research laboratory setting that mimics a construction site and in the Gazebo simulation. Integrating the flexibility of human workers and the autonomy and accuracy afforded by the BIM, the proposed framework offers significant promise of increasing the robustness of construction robots in the performance of field construction work.

Analysis of musculoskeletal pains and productivity impacts among hispanic construction workers

This study investigated the top three musculoskeletal pains (MSP) among Hispanic construction workers in Texas and the relationship between sleep hours, age, and MSPs on worker productivity. The study recruited 228 participants from 28 small construction companies and surveyed them on their occupation, age, sleep hours, MSP, and the impact of pain on productivity. The results indicated that Foot pain was the most common among these workers, followed by Back pain and others. Additionally, the study found that the Foot was the most common body part reported with MSP among roofers, drywall installers, laborers, and helpers. The study conducted a three-factor ANOVA test to analyze if there were any significant differences in productivity based on age, number of MSPs, and sleep hours. The study found that MSPs and sleep hours significantly impacted productivity. However, there was no significant effect of age. The results also showed that the number of MSPs significantly impacted productivity, with an increase in MSPs leading to a more severe impact on productivity. Additionally, those who slept less than 6 h per day had a more severe impact on productivity than those who slept more. The study suggests that targeted interventions to improve musculoskeletal health and productivity in this population are needed and highlights the importance of considering Hispanic construction workers' specific needs when implementing safety measures and addressing pain management in the workplace.

Ontology-Based Semantic Construction Image Interpretation

Image-based techniques have become integral to the construction sector, aiding in project planning, progress monitoring, quality control, and documentation. In this paper, we address two key challenges that limit our ability to fully exploit the potential of images. The first is the “semantic gap” between low-level image features and high-level semantic descriptions. The second is the lack of principled integration between images and other digital systems used in construction, such as construction schedules and building information modeling (BIM). These challenges make it difficult to effectively incorporate images into digital twins of construction (DTC), a critical concept that addresses the construction industry’s need for more efficient project management and decision-making. To address these challenges, we first propose an ontology-based construction image interpretation (CII) framework to formalize the interpretation and integration workflow. Then, the DiCon-SII ontology is developed to provide a formalized vocabulary for visual construction contents and features. DiCon-SII also acts as a bridge between images and other digital systems to help construct an image-involved DTC. To evaluate the practical application of DiCon-SII and CII in supporting construction management tasks and as a precursor to DTC, we conducted a case study involving drywall installation. Via this case study, we demonstrate how the proposed methods can be used to infer the operational stage of a construction process, estimate labor productivity, and retrieve specific images based on user queries.

Comparison of on-site and off-site robot solutions to the traditional framing and drywall installation tasks

Comparison of on-site and off-site robot solutions to the traditional framing and drywall installation tasks

A deep learning-based approach to facilitate the as-built state recognition of indoor construction works

PurposeRecognising the as-built state of construction elements is crucial for construction progress monitoring. Construction scholars have used computer vision-based algorithms to automate this process. Robust object recognition from indoor site images has been inhibited by technical challenges related to indoor objects, lighting conditions and camera positioning. Compared with traditional machine learning algorithms, one-stage detector deep learning (DL) algorithms can prioritise the inference speed, enable real-time accurate object detection and classification. This study aims to present a DL-based approach to facilitate the as-built state recognition of indoor construction works.Design/methodology/approachThe one-stage DL-based approach was built upon YOLO version 4 (YOLOv4) algorithm using transfer learning with few hyperparameters customised and trained in the Google Colab virtual machine. The process of framing, insulation and drywall installation of indoor partitions was selected as the as-built scenario. For training, images were captured from two indoor sites with publicly available online images.FindingsThe DL model reported a best-trained weight with a mean average precision of 92% and an average loss of 0.83. Compared to previous studies, the automation level of this study is high due to the use of fixed time-lapse cameras for data collection and zero manual intervention from the pre-processing algorithms to enhance visual quality of indoor images.Originality/valueThis study extends the application of DL models for recognising as-built state of indoor construction works upon providing training images. Presenting a workflow on training DL models in a virtual machine platform by reducing the computational complexities associated with DL models is also materialised.

Controlling safety and health challenges intrinsic in exoskeleton use in construction

Construction practitioners have started exploring the use of exoskeletons within operations to combat the high rate of work-related musculoskeletal disorders, declining productivity, and worker attrition. In attempting to adopt exoskeletons, the ensuing human-robot interaction (HRI) can lead to the emergence of novel safety risks or the increment of existing safety risks as a result of hazards peculiar to the task-technology execution. These risks, if ignored, can worsen construction worker safety performance. This paper presents research aimed at developing insights needed to control safety risks associated with exoskeleton (wearable robot) use across three construction tasks – bricklaying, drywall installation, and concrete grinding and polishing. To achieve this aim, the Delphi method, which relied on inferential and descriptive statistics such as mean analysis and consensus evaluation, was employed to (1) quantify wearable robot safety risks for selected construction tasks, and (2) identify effective and feasible safety risk mitigation strategies using the study results. Findings from the present study include 10 critical safety and health risks associated with exoskeletons and 12 key safety risk mitigation strategies. This research contributes to knowledge by characterizing the safety risks and mitigation strategies associated with HRI and providing valuable insights that could be used by researchers to advance construction worker safety and health research. Through increased awareness of HRI safety risk and mitigation strategies, practitioners can prioritize safety resources and improve worker safety and productivity.

Interactive and Immersive Process-Level Digital Twin for Collaborative Human–Robot Construction Work

Human cognition plays a critical role in construction work, particularly in the context of high-level task planning and in-field improvisation. On the other hand, robots are adept at performing numerical computation and repetitive physical tasks with precise motion control. The unstructured and complex nature of construction environments and the inability to maintain tight tolerances in assembled workpieces pose several unique challenges to the wide application of robots in construction work. Thus, the robotization of field construction processes is best conceived as a collaborative human–robot endeavor that takes advantage of both human and robot intelligence as well as robots’ physical operation capabilities to overcome uncertainties and successfully perform useful construction work onsite. This paper proposes an interactive and immersive process-level digital twin (I2PL-DT) system in virtual reality (VR) that integrates visualization and supervision, task planning and execution, and bidirectional communication to enable collaborative human–robot construction work. In this work paradigm, the human worker is responsible for high-level task planning and work process supervision. The robot undertakes workspace sensing and monitoring, detailed motion planning, and physical execution of the work. A drywall installation case study involving imperfect rough carpentry (wall framing) is presented using a KUKA mobile industrial robotic arm emulator. A human-in-the-loop study involving 20 subjects was conducted for system verification and to collect feedback for future improvements. The experimental results show that users can use the system to specify work sequences, select optimal task plans, and perform robot trajectory guidance after simple training and felt positive about the system functions and user experience. The system demonstrates the potential of transitioning the role of construction workers from physical task performers to robot supervisors. In addition, the system establishes a promising framework for construction workers to remotely collaborate with onsite construction robots.

Building Information Modelling‐ (BIM‐) Based Generative Design for Drywall Installation Planning in Prefabricated Construction

In prefabricated construction, building components are manufactured off‐site before shipping to the site for installation. Accurate design and planning are essential for smooth on‐site execution and improved efficiency, which requires evaluations of various design options. However, due to the design process’s complexity, such evaluations cannot be achieved without automation and optimization. Meanwhile, the recent advancement of digital design technologies (e.g., building information modelling (BIM)) has enabled flexibility in the design process. The integration of BIM with other analytical algorithms also allows optimization of designs, such as the generative design that can parametrize the design. This study proposes a generative design approach that utilizes the optimization of the drywall installation layout to improve overall project efficiency. The framework includes a decision support module that considers environmental, cost, and aesthetic aspects to identify the optimal layout. The framework’s practical applicability has been successfully demonstrated through a case study. After implementation, three “best” design alternatives were found according to the decision aspects. The design improvements achieved were 37.5%, 7%, and 54% for the environmental, cost, and aesthetic factors, respectively. Accordingly, practitioners can make better decisions on planning drywall projects. This approach has proven effective in planning drywall installation and can be applied in similar design scenarios for other prefabricated construction processes.

Does the format of design information affect hazard recognition performance in construction hazard prevention through design reviews?

A series of simulated design for safety reviews with civil engineering students, construction and engineering designers, and construction supervisors were conducted across the United States to explore the effects that different formats of design information have on hazard recognition performance during construction hazard prevention through design (CHPtD) reviews. In total, 117 participants were provided one of three information formats including: two-dimensional (2D) computer aided design (CAD) drawings, three-dimensional (3D) computerized visualizations, and a combination of the two (2D & 3D). Participants were randomly assigned to treatment groups using blocked counterbalanced design. In the experiment, participants were asked to explore the design and identify as many safety hazards as possible for three separate construction work activities: rooftop skylight installation, interior soffit drywall installation, and interior metal wall stud framing. Mean and dispersion and ANOVA tests suggest that the format of design information did not have any significant effects on the hazard recognition skill during CHPtD reviews. These findings challenge the pervasive assumption that three-dimensional design information is superior to two-dimensional information in terms of safety planning. The primary theoretical contribution of this research lies in the exploration of how design information affects the ability of an individual to forecast and address construction dangers from different abstractions of the target facility. The practical implication of the findings is that the format of design information may be far less important than the experience of the professionals and the time they invest in searching for and correcting hazards.

Characterization of load reduction while lifting drywall using an unpowered drywall lifting device

Drywall installation has an injury rate four times that of the construction industry average. Workers are exposed to hazards related to slips, falls, and falling objects, in addition to the large and awkward loads they must carry. Drywall sheets can weigh more than 100 lb. and contribute to disabling musculoskeletal injuries of the shoulders and back. In this study, an unpowered lift assist device was developed to manage the load of a drywall sheet during the installation process. In order to measure the effect of the lift assist device, a laboratory study with 10 healthy male participants performing two lifts, lifting from ground to erect and lifting from erect to ceiling, with and without the help of the device, was performed. These lifts were chosen to simulate a drywall installer's frequent lifting motions. Participants were fitted with electromyography (EMG) on the erector spinae, latissimus dorsi, rectus abdominus, and external oblique muscles to measure activation. Mean, peak, and effort data for the lifting exercises were extracted and compared to the unassisted lift. The lift assist device resulted in a reduction in mean EMG signal of 69% average over both lifts and muscle groups. Peak EMG and effort (i.e., area under the curve) were reduced by 78% and 75%, respectively. These data demonstrate the effectiveness of the device in reducing compressive back loads during drywall installation, which warrants future development.

Does drywall installers' innovative idea reduce the ergonomic exposures of ceiling installation: A field case study

ObjectiveThe study was conducted to assess an intervention suggested by the workers to reduce the physical or ergonomic exposures of the drywall installation task. MethodsThe drywall installers were asked to brainstorm on innovative ideas that could reduce their ergonomic exposures during the drywall installation work. The workers proposed the idea of using a ‘deadman’ (narrow panel piece) to hold the panels to the ceiling while installing them. The researcher collected quantitative exposure data (PATH, 3DSSPP) at the baseline and intervention phases and compared the phases to find out any change in the exposure while using the ‘deadman’. ResultsResults showed that ergonomic exposures (such as overhead arm and awkward trunk postures and heavy load handling) were reduced at the intervention phase while using the ‘deadman’ with an electrically operated lift. ConclusionThe concept of the ‘deadman’, which was shown to help reduce musculoskeletal exposures during ceiling installation, can be used to fabricate a permanent ergonomic tool to support the ceiling drywall panel.

An integrated biomechanical modeling approach to the ergonomic evaluation of drywall installation

Three different methodologies: work sampling, computer simulation and biomechanical modeling, were integrated to study the physical demands of drywall installation. PATH (Posture, Activity, Tools, and Handling), a work-sampling based method, was used to quantify the percent of time that the drywall installers were conducting different activities with different body segment (trunk, arm, and leg) postures. Utilizing Monte-Carlo simulation to convert the categorical PATH data into continuous variables as inputs for the biomechanical models, the required muscle contraction forces and joint reaction forces at the low back (L4/L5) and shoulder (glenohumeral and sternoclavicular joints) were estimated for a typical eight-hour workday. To demonstrate the robustness of this modeling approach, a sensitivity analysis was conducted to examine the impact of some quantitative assumptions that have been made to facilitate the modeling approach. The results indicated that the modeling approach seemed to be the most sensitive to both the distribution of work cycles for a typical eight-hour workday and the distribution and values of Euler angles that are used to determine the “shoulder rhythm.” Other assumptions including the distribution of trunk postures did not appear to have a significant impact on the model outputs. It was concluded that the integrated approach might provide an applicable examination of physical loads during the non-routine construction work, especially for those operations/tasks that have certain patterns/sequences for the workers to follow.

Workers' compensation claims for musculoskeletal disorders and injuries of the upper extremity and knee among union carpenters in Washington State, 1989-2008.

Numerous aspects of construction place workers at risk of musculoskeletal disorders and injuries (MSDIs). Work organization and the nature of MSDIs create surveillance challenges. By linking union records with workers' compensation claims, we examined 20-year patterns of MSDIs involving the upper extremity (UE) and the knee among a large carpenter cohort. MSDIs were common and accounted for a disproportionate share of paid lost work time (PLT) claims; UE MSDIs were three times more common than those of the knee. Rates declined markedly over time and were most pronounced for MSDIs of the knee with PLT. Patterns of risk varied by extremity, as well as by age, gender, union tenure, and predominant work. Carpenters in drywall installation accounted for the greatest public health burden. A combination of factors likely account for the patterns observed over time and across worker characteristics. Drywall installers are an intervention priority.

Interventions to Reduce the Ergonomic Exposures of Drywall Installation

The study was conducted to assess the efficacy of an assistive tool to reduce the physical exposures of the ceiling installation task. Based on the idea of using a ‘deadman’ (long narrow piece of panel) to help hold the panels on the ceiling while installing them, a prototype tool was fabricated that could be placed on its own while supporting the ceiling. This tool, which was introduced to the drywall foremen and ceiling installers at a construction site, was implemented as an intervention for the ceiling installation process. To evaluate the efficacy of this tool for exposure reduction, the researcher collected quantitative exposure data (PATH) and qualitative data at the baseline and intervention phases. The data at the two time periods were compared to evaluate any change in the exposure with use of the tool. Results showed that physical exposures (such as overhead arm, postures, heavy load handling, load handling while holding the panels with arms raised while being on a ladder) were reduced while using the tool at the intervention phase. Reduction of physical ergonomic exposures by the use of the prototype tool is evident in the result while the tool itself was a better version of the ‘deadman’ regarding its easy usage and self-supporting structure i.e., the installers need not hold it under the ceiling.

The effects of position and size of drywall on the physical demands for installers

The present study utilized an integrated biomechanical modeling approach that was previously developed by the researchers to investigate the effects of position and size of drywall on the physical demands for drywall installers. If the drywall sheets were stored vertically instead of flat, it reduced the required muscle contraction forces and joint reaction forces at the low back and shoulder approximately 8% on average during drywall installation. In particular, the L4/L5 disc compression forces and the absolute values of L4/L5 anterior-posterior shear forces decreased 6.1% and 8.5%, respectively, and at the shoulder during lifting the forces of rotator cuff muscles decreased 9.8%, and the coracohumeral ligament forces decreased 12.8%. The reaction forces at both the GH (glenohumeral) and SC (sternoclavicular) joints were reduced 7.2% and 3.6%, respectively. The larger size (e.g., 4x12 and 4x16) of drywall sheets increased the physical burden for the installers tremendously and could expose them to a higher risk of musculoskeletal injuries and disorders. In some simulations the average low back lateral shear forces increased to 1675 N and 2152 N, respectively. These forces are well above the 1000 N recommended for a single lift. These results indicated that it would be physically too difficult or even impossible for one person alone to lift bigger and heavier drywall sheets. Therefore, sound engineering (e.g., lifting tables) and/or administrative (e.g., two-person team work) solutions to handling oversized drywall sheets are strongly recommended.

0344 20 years (1989–2008) of direct costs associated with falls from height among union carpenters, Washington State, USA

ObjectivesTo examine trends in workers’ compensation payments for falls from height (FFH) among a large cohort of carpenters over a 20-year period (1989–2008). Cost data provide an important metric reflecting...

Assessing the ergonomic exposures for drywall workers

ObjectiveThe study was conducted to assess the ergonomic exposures to risk factors that may lead to the reported musculoskeletal injuries (especially back, neck and wrist injuries) of drywall workers. MethodsA hierarchical taxonomy for construction of drywall panel hanging (drywall panel fitting and installation) was developed with activities defined within the interior wall systems tasks (drywall panel, studs and insulation). Exposures were characterized for the drywall panel work with the PATH (Posture, Activity, Tools, and Handling) work-sampling observation method. Data on working postures were collected for three main body parts: legs, arms and trunk. Activities performed for each task, tools used, and manually handled loads were also recorded for each observation. ResultsThe study identified several ergonomic exposures in interior systems construction. Several risk factors were especially prevalent in the drywall panel installation task: awkward body postures such as overhead arm posture, trunk flexion, and handling of heavy drywall panels. Some tasks were observed to have combinations of these musculoskeletal risk factors, such as drywall panel installation, where the workers lifted heavy drywall panels in awkward body postures. In addition, a safety hazard frequently resulted when a worker's foot was poorly supported on a ladder while lifting heavy drywall panels to hang them on the ceiling or upper wall. ConclusionThe drywall panel installation task poses a severe threat to the safety and musculoskeletal health of the drywall workers. Much of this could be eliminated by reducing the burden of handling heavy and bulky drywall panels. Relevance to industryThe construction industry is well-documented to have high rates of injury and musculoskeletal disorders. Design of appropriate interventions requires specific knowledge of which tasks and activities involve the highest levels of exposure to relevant factors. Assessment of such factors in drywall panel hanging has provided data that will be useful to evaluate the ergonomics efficacy of future changes in task processes or tools. Feasible solutions appear to exist; effectiveness trials and worker input are needed in order to evaluate whether they could eliminate the observed exposures.

298 Falls from elevation among union drywall installers: Patterns in rates of injury and the utility of event narratives

ObjectivesDespite prevention efforts over the past several decades, drywall installers in the US remain at risk for work-related falls from elevation. These workers are challenging to study from an epidemiologic...

An Innovative Idea for Reducing the Musculoskeletal Disorders in Drywall Installation

Objective: The study was conducted to assess an intervention suggested by the workers to reduce the ergonomic exposures of the drywall installation task. Methods: At several focus group meetings the drywall installers were asked to brainstorm on innovative ideas that could reduce their ergonomic/musculoskeletal exposures during the drywall installation work. The workers discussed the idea of using a ‘deadman’ (long narrow piece of sheetrock) to help hold the panels on the ceiling while installing them. The researcher collected quantitative exposure data (PATH, 3DSSPP) at the baseline and intervention phases. The data at the two time periods were compared to find out any change in the exposure with use of the ‘deadman’. Results: Results showed that exposures (such as overhead arm and awkward trunk postures and heavy load handling) were reduced in the intervention phase while using an electrical lift and the ‘deadman’. Conclusion: The concept of the ‘deadman’, which was shown to help reduce musculoskeletal exposures during ceiling installation, can be used to fabricate a permanent ergonomic tool to support the ceiling sheetrock.

Declining rates of work‐related overexertion back injuries among union drywall installers in Washington State, 1989–2008: Improved work safety or shifting of care?

Construction workers are at high risk of work-related musculoskeletal back disorders, and research suggests medical care and costs associated with these conditions may be covered by sources other than workers' compensation (WC). Little is known about the back injury experience and care seeking behavior among drywall installers, a high-risk workgroup regularly exposed to repetitive activities, awkward postures, and handling heavy building materials. Among a cohort of 24,830 Washington State union carpenters (1989-2008), including 5,073 drywall installers, we identified WC claims, visits for health care covered through union-provided health insurance and time at risk. Rates of work-related overexertion back injuries (defined using WC claims data) and health care utilization for musculoskeletal back disorders covered by private health insurance were examined and contrasted over time and by worker characteristics, stratified by type of work (drywall installation, other carpentry). Drywall installers' work-related overexertion back injury rates exceeded those of other carpenters (adjusted IRR 1.63, 95% CI 1.48-1.78). For both carpentry groups, rates declined significantly over time. In contrast, rates of private healthcare utilization for musculoskeletal back disorders were similar for drywall installers compared to other carpenters; they increased over time (after the mid-1990s), with increasing years in the union, and with increasing numbers of work-related overexertion back injuries. Observed declines over time in the rate of work-related overexertion back injury, as based on WC claims data, is encouraging. However, results add to the growing literature suggesting care for work-related conditions may be being sought outside of the WC system.