Automated geometry quality assessment of precast concrete elements using 3D laser scan data

Precast concrete elements are popularly adopted in buildings and civil infrastructures like bridges because they provide well-controlled quality, reduced construction time, and less environmental impact. To ensure the performance of complete precast concrete structures, individual precast concrete elements must be cast according to the as-designed blueprints. Any inconsistency between the as-built and as-designed dimensions can result in assembly difficulty or structure failure, causing delay and additional cost. Therefore, it is essential to conduct geometry quality assessment for precast concrete elements before they are shipped to the construction sites. Currently, the quality assessment of precast concrete elements is still relying on manual inspection, which is time-consuming and labor-intensive. Besides, due to tedious work, manual inspection is also error-prone and unreliable. Thus, automated, efficient, and accurate approaches for geometry quality assessment of precast concrete elements are desired. Nowadays, 3D laser scanning has been widely applied to the quality assessment of buildings and civil infrastructures because it can acquire 3D range measurement data at a high speed and high accuracy. However, existing research of laser scanning based quality assessment is mainly focused on simple-geometry elements, such as straight columns and rectangular concrete surfaces. There has been limited research on the quality assessment of precast concrete elements with complex shapes. To tackle the limitations of existing research, this research aims to develop automated, efficient, and accurate techniques for the geometry quality assessment of precast concrete elements using 3D laser scan data. The geometry quality assessment includes dimensional quality assessment, surface flatness and distortion assessment, and rebar position assessment. For dimensional quality assessment, a dimensional quality assessment technique focusing on the side surfaces of precast concrete panels is developed. This technique aligns the laser scan data with the as-designed building information model (BIM), and extracts the as-built dimensions of the elements. Furthermore, an improved dimensional quality assessment and as-built BIM creation technique is developed to inspect the entire precast concrete element, rather than a surface only, and to automatically create a BIM model for storing the as-built dimensions for better visualization and management. As a supporting study, a novel mixed pixel filter is developed to remove noise data namely mixed pixels from raw laser scan data and to improve the dimension estimation accuracy. The proposed mixed pixel filter formulates the locations of mixed pixels, based on which the optimal threshold value is obtained to classify scan data into mixed pixels and valid points. Another supporting study is to investigate the influence factors for edge line estimation accuracy. Four influence factors are identified and the effect of each factor is analyzed based on numerical simulations. Implications are eventually suggested based on the analysis. For surface flatness and distortion assessment, the developed technique identifies a few measures for both surface flatness and distortion. These measures are then automatically calculated from the laser scan data of the precast concrete surface for surface quality assessment. Furthermore, an automated rebar position estimation technique is developed to estimate the rebar positions for rebar positioning quality assessment. The technique can recognize individual rebars from the laser scan data of reinforced precast concrete elements and accurately estimate the rebar positions. This research provides automated approaches for the quality assessment of precast concrete elements, which are able to greatly save the labor cost and time for quality assessment. In addition, the quality of precast concrete structures can be improved due to the faster and more economical quality assessment, thereby further promoting the adoption of precast concrete elements in the const uction industry.